cls user's guide - westcoastplastics.com€¦ · cls user’s guide part no. 21952-00....

CLSUser’s Guide

Part No. 21952-00. Revision 3.2October 1996

Watlow Controls1241 Bundy Blvd.Winona, MN 55987

Customer ServicePhone: (800) 414-4299Fax: (800) 445-8992

Technical SupportPhone: (507) 494-5656Fax: (507) 452-4507Email: [email protected]

Copyright © 1996Watlow Anafaze

Information in this manual is subject to change without notice. No part of this publication may bereproduced, stored in a retrieval system, or transmitted in any form without written permissionfrom Watlow Anafaze.

Warranty

Watlow Anafaze, Incorporated warrants that the products furnished under this Agreement will befree from defects in material and workmanship for a period of three years from the date of ship-ment. The Customer shall provide notice of any defect to Watlow Anafaze, Incorporated within oneweek after the Customer's discovery of such defect. The sole obligation and liability of WatlowAnafaze, Incorporated under this warranty shall be to repair or replace, at its option and withoutcost to the Customer, the defective product or part.

Upon request by Watlow Anafaze, Incorporated, the product or part claimed to be defective shallimmediately be returned at the Customer's expense to Watlow Anafaze, Incorporated. Replaced orrepaired products or parts will be shipped to the Customer at the expense of Watlow Anafaze,Incorporated.

There shall be no warranty or liability for any products or parts that have been subject to misuse,accident, negligence, failure of electric power or modification by the Customer without the writtenapproval of Watlow Anafaze, Incorporated. Final determination of warranty eligibility shall bemade by Watlow Anafaze, Incorporated. If a warranty claim is considered invalid for any reason,the Customer will be charged for services performed and expenses incurred by Watlow Anafaze,Incorporated in handling and shipping the returned unit.

If replacement parts are supplied or repairs made during the original warranty period, the warrantyperiod for the replacement or repaired part shall terminate with the termination of the warrantyperiod of the original product or part.

The foregoing warranty constitutes the sole liability of Watlow Anafaze, Incorporated and the Cus-tomer's sole remedy with respect to the products. It is in lieu of all other warranties, liabilities, andremedies. Except as thus provided, Watlow Anafaze, Inc. disclaims all warranties, express orimplied, including any warranty of merchantability or fitness for a particular purpose.

Please Note: External safety devices must be used with this equipment.

CLS User’s Guide Contents

i

Contents

Overview 1

System Diagram.....................................................................2Parts List ...............................................................................2Safety .....................................................................................3

Introduction 5

Specifications ........................................................................7Analog Inputs ..................................................................7Digital Inputs ..................................................................9User-Selectable Digital Outputs .....................................9System Digital Outputs ....................................................9Analog Outputs ................................................................10

Miscellaneous Specifications ................................................11Physical Dimensions .......................................................11

Installation 13

Precautions and Warnings ....................................................14Recommended Tools ............................................................15

Panel Hole Cutters ..........................................................15Other Tools .....................................................................15

CLS Mounting Procedure .....................................................16Mounting Environment ...................................................16Steps: ...............................................................................16

TB-18 Mounting Instructions ...............................................17TB-50 Mounting Instructions ...............................................18General Wiring Recommendations .......................................20

Grounding .......................................................................21Thermocouple Wiring .....................................................22Input Wiring ....................................................................22Output Wiring .................................................................23Communications Wiring .................................................23

Wiring: Noise Suppression ...................................................24General Wiring .....................................................................25

Power Wiring and Controller Test ..................................25Outputs ..................................................................................27

PID Control and Alarm Output Connections 2................30Watchdog Timer .............................................................30TB-18 Connections .........................................................31TB-50 Connections .........................................................32

ii

Contents CLS User’s Guide

Inputs ....................................................................................34Input Scaling ...................................................................344 and 8 CLS Scaling Values ...........................................3516 CLS Scaling Values ...................................................38Scaling and Calibration ...................................................39T/C Inputs .......................................................................39RTD Inputs (4 and 8 CLS only) ......................................40Current Inputs .................................................................41Voltage Inputs .................................................................41Unused Inputs .................................................................41Back Terminal Block Connections .................................42

Serial Communications .........................................................42RS-232 Interface .............................................................43RS-485 Interface .............................................................43

Using the CLS 49

Introduction ...........................................................................49Front Panel ............................................................................50

Front Panel Keys .............................................................50Displays ................................................................................53

Bar Graph Display ..........................................................53Single Loop Display .......................................................54Alarms .............................................................................56

Job Display ...........................................................................57Operator Menus ....................................................................58

Change Setpoint ..............................................................58Manual/Automatic Control .............................................58Ramp/Soak ......................................................................60

Setup 61

How to Enter the Setup Menus? .....................................61How to edit a menu? .......................................................61

Set up Global Parameters Menu ...........................................63Load a Job .......................................................................64Save Setup to Job ............................................................64Job Select Inputs .............................................................65Job Select Input Polarity .................................................65Output Override Digital Input .........................................66Output Override Input Polarity .......................................66Start-up Alarm Delay ......................................................66Keyboard Lock Status .....................................................67Power-Up Output Status .................................................67Controller Address ..........................................................67Communications Baud Rate ............................................68


iii

Communications Protocol ...............................................68Communications Error Checking ...................................68AC Line Frequency .........................................................69Digital Output Polarity ....................................................69EPROM Information .......................................................69

Set up Loop Input .................................................................70Input Type .......................................................................71Pulse Sample Time .........................................................72Loop Name .....................................................................72Input Units ......................................................................72Input Reading Offset .......................................................73Linear Scaling Menus .....................................................73Display Format ...............................................................75High Process Value .........................................................75High Reading ..................................................................76Low Process Value .........................................................76Low Reading ...................................................................76Input Filter ......................................................................77

Set up Loop Control Parameters ...........................................78Heat or Cool Control PB .................................................79Heat or Cool Control TI ..................................................79Heat or Cool Control TD ................................................79Heat or Cool Output Filter ..............................................80Heat and Cool Spread .....................................................80

Set up Loop Outputs .............................................................81Enable/Disable Heat or Cool Outputs .............................82Heat or Cool Output Type ..............................................82Heat or Cool Cycle Time ................................................83

SDAC Menus ........................................................................83SDAC Mode ...................................................................83SDAC High Value ..........................................................84SDAC Low Value ...........................................................84Heat or Cool Output Action ............................................84Heat or Cool Output Limit ..............................................85Heat or Cool Output Limit Time ....................................85Heat or Cool Output Override ........................................85Heat or Cool Nonlinear Output Curve ............................86

Set up Loop Alarms ..............................................................87Alarm Types ...................................................................87High Process Alarm Setpoint ..........................................90High Process Alarm Type ...............................................90High Process Alarm Output Number ..............................90Deviation Band Value .....................................................91High Deviation Alarm Type ...........................................91

iv

Contents CLS User’s Guide

High Deviation Alarm Output Number ..........................91Low Deviation Alarm Type ............................................92Low Deviation Alarm Output Number ...........................92Low Process Alarm Setpoint ..........................................92Low Process Alarm Type ...............................................93Low Process Alarm Output Number ..............................93Alarm Deadband .............................................................93Alarm Delay.....................................................................94

Manual I/O Test ....................................................................95Digital Input Testing .......................................................95Test Digital Output .........................................................96Toggle Digital Output .....................................................96Keypad Test ....................................................................96

PID Tuning and Control 97

Introduction ...........................................................................97Control Modes ......................................................................98

On/Off Control ................................................................98Proportional Control .......................................................98Proportional and Integral Control ...................................99Proportional, Integral and Derivative Control ................100Control Outputs ...............................................................100Digital Output Control Forms .........................................100

Setting Up and Tuning PID Loops .......................................103Proportional Band (PB) Settings .....................................103Integral Term (TI) Settings .............................................104Derivative Term (TD) Settings .......................................104

General PID Constants by Application .................................105Proportional Band Only (P) ............................................105Proportional with Integral (PI) ........................................105PI with Derivative (PID) .................................................105

Troubleshooting 107

No Key Reset ..................................................................107Returning your Unit ........................................................108

Troubleshooting Stand-Alone Systems ................................108Checking an Analog Input ..............................................108Checking Digital I/O .......................................................109

Checking Computer Supervised Systems .............................110Computer Problems ........................................................110Software Problems ..........................................................111Changing the EPROM ....................................................111


v

Linear Scaling Examples 115

Example 1 .............................................................................115Example 2 .............................................................................116Example 3 .............................................................................117

Appendix A: Ramp Soak 119

Introduction ...........................................................................119R/S Features ....................................................................119Specifications ..................................................................120

Configuring Ramp/Soak .......................................................120Setting the R/S Time Base ..............................................121Editing R/S Parameters ...................................................121Choosing a Profile to Edit ...............................................121Copying the Setup from Another Profile ........................122Editing the tolerance Alarm Time ..................................122Editing the Ready Setpoint .............................................123Editing the Ready Event States .......................................123Choosing an External Reset Input ..................................124Editing a Segment ...........................................................124Setting Segment Time .....................................................124Setting a Segment Setpoint .............................................125Configuring Segment Events ..........................................125Editing Event Outputs .....................................................126Changing Event States ....................................................126Editing Segment Triggers ...............................................126Assigning an Input to a Trigger ......................................127Changing a Trigger’s True State .....................................127Latching or Unlatching a Trigger ...................................127Setting Segment Tolerance .............................................128Ending a Profile ..............................................................128Repeating a Profile ..........................................................128

Using Ramp/Soak .................................................................129Assigning a profile to a loop ...........................................129Assigning a Profile to a Linear Input Loop ....................130Running a Profile ............................................................131Ramp/Soak Displays .......................................................131Holding a Profile or Continuing from Hold ....................134Resetting a profile ...........................................................135

Appendix B: Enhanced Process Control 137

Enhanced Process Control Menus ........................................138

vContents CLS User’s Guide

Process Variable Retransmit .................................................139Setting Up a PV Retransmit ............................................139PV Retransmit Menus .....................................................140

Cascade Control ....................................................................143Setting Up Cascade Control ............................................143Cascade Control Menus ..................................................144

Ratio control .........................................................................147Setting Up Ratio Control ................................................147Ratio Control Menus .......................................................148

Remote Analog setpoint ........................................................149Differential Control ...............................................................149Typical Applications .............................................................150

Process Variable Retransmit ...........................................150Cascade Control ..............................................................153Ratio Control ...................................................................156Remote Setpoint ..............................................................158Differential Control .........................................................159

Glossary 163

Overview

OverviewThis manual describes how to install, setup, and operate a 4CLS, an8CLS, or a 16CLS. Included are seven chapters, two Appendices, and aglossary of terms. Each chapter covers a different aspect of your controlsystem and may apply to different users. The following describes thechapters and their purpose.

• Introduction: Gives a general description of the CLS and its related specifications.

• Installation: Describes how to install the CLS and its peripheral devices.

• Using the CLS: Provides an overview of operator displays used for system monitoring.

• Setup: Describes all the setup displays for the controller, and how to access them.

• Tuning and Control: Explains PID control and provides tips for tuning your system.

• Troubleshooting: Gives some basic guidelines for solving control problems.

• Linear Scaling Examples: Provides an example configuring a pres-sure sensor, and one configuring a flow sensor.

• Appendix A: Ramp and Soak. This section explains how to setup and use Ramp/Soak profiles in your application.

• Appendix B: Enhanced Process Control. This appendix describes optional process variable retransmit and cascade control features.

CLS User’s Guide 1

Overview

System Diagram

The illustration below shows how the parts of the CLS are connected.When unpacking your system, use the diagrams and parts list below toensure all parts have been shipped. Please don't hesitate to call WatlowAnafaze's Technical Service Department if you have problems withyour shipment, or if the CLS components are missing or damaged.

.

Parts List

• CLS controller

• Controller mount kit

• AC adapter (110V or 220V)

• Terminal Block (TB-50 or TB-18)

• TB-50 or TB-18 mounting kit

• 50 pin flat ribbon cable (50 pin ribbon cable)

• DAC or SDAC (optional)

• User Manual

2 CLS User’s Guide

Overview

Safety

Watlow Anafaze has made efforts to ensure the reliability and safety ofthe CLS Controller and to recommend safe usage practices in systemsapplications. Please note that, in any application, failures can occur.These failures may result in full control outputs or other outputs whichmay cause damage to or unsafe conditions in the equipment or processconnected to the CLS Controller.

Good engineering practices, electrical codes, and insurance regulationsrequire that you use independent external safety devices to preventpotentially dangerous or unsafe conditions. Assume that the WatlowAnafaze CLS Controller can fail with outputs full on, outputs full off, orthat other unexpected conditions can occur.

Install high or low temperature protection in systems where anovertemperature or undertemperature fault condition could present a firehazard or other hazard. Failure to install temperature control protectionwhere a potential hazard exists could result in damage to equipment andproperty, and injury to personnel.

The CLS includes a reset circuit that sets the control outputs off or to thedata stored in memory if the microprocessor resets--normally the resultof a power failure and power return. If a memory-based restart will beunsafe for your process, program the CLS Controller to restart withoutputs off. For additional safety, program the computer or other hostdevice to automatically reload the desired operating constants or processvalues on return of operating power. However, these safety features donot eliminate the need for external, independent safety devices inpotentially dangerous or unsafe conditions.

Watlow Anafaze also offers ANASOFT®, an optional software

program for IBM-AT® or IBM-PC® compatible computers. In theevent of a reset, ANASOFT will reload the CLS Controller with thecurrent values in computer memory. The user must ensure that this resetwill be safe for the process. Again, use of ANASOFT does not eliminatethe need for appropriate external, independent safety devices.

Contact Watlow Anafaze immediately if you have any questions aboutsystem safety or system operation.


Overview


Introduction

IntroductionThe CLS is a modular control system with up to 16 fully independentloops of PID control (16 CLS). It functions as a stand-alone controller;the CLS 1/8 DIN front panel has a Liquid Crystal Display (LCD) andtouch keypad for local display and local parameter entry. You can alsouse it as the key element in a computer-supervised data acquisition andcontrol system; the CLS can be locally or remotely controlled via anRS-232 or RS-485 serial communications interface.

The CLS features include:

Direct Connection of Mixed Thermocouple Sensors: Directlyconnect most thermocouples with the CLS versatile hardware.Thermocouple inputs feature reference junction compensation,linearization, PV offset calibration to correct for sensor inaccuracies, T/C upscale break detection, and a choice of Fahrenheit or Celsius display.

Resistive Temperature Detector Sensors are Standard Inputs: Twotypes of standard three wire 100 ohm platinum DIN curve sensor arestandard inputs for the CLS. (To use this input, order the CLS withscaling resistors.)

Automatic Scaling for Linear Analog Inputs: The CLS automaticallyscales linear inputs used with other industrial process sensors. Simplyenter two measurement points. For example, to scale a PSI sensor enterthe endpoints: Low PV is 10 PSI, while High PV is 100 PSI. All othervalues for that loop will automatically be in PSI.

Dual Outputs Standard: The CLS includes dual control outputs foreach loop, with independent control constants for each output.

Independently Selectable PID Output Modes: You can set eachcontrol output to ON/OFF, Time Proportioning, Serial DAC, orDistributed Zero Crossing mode. You can set each output control modefor ON/OFF, P, PI, or PID control with reverse or direct action.

Flexible Alarm Outputs: Independently set high/low process alarmsand a high/low deviation band alarm for each loop. Alarms can activatea digital output by themselves, or they can be grouped with other alarmsto activate an output.

Alarm or Control Outputs: You can set high/low deviation and high/low process setpoints to operate digital outputs as on/off controlfunctions instead of alarms. (The control function has no alarmnotification or global alarm output.)

Global Alarm Output: When any alarm is triggered, the Global AlarmOutput is also triggered, and it stays on until you acknowledge it.


Introduction

Watchdog Timer: The CLS watchdog timer output notifies you ofsystem failure. You can use it to hold a relay closed while the controlleris running, so you are notified if the microprocessor shuts down.

Front Panel or Computer Operation: Set up and run the CLS fromthe front panel or from a local or remote computer. Watlow Anafazeoffers ANASOFT, our IBM AT or IBM-PC compatible software you canuse to operate the CLS. ANASOFT has these features:

• Process Overviews

• Parameter Setup

• Graphic Trend Plotting

• Data Logging

Multiple Job Storage: Store up to 8 jobs in protected memory, andaccess them locally by entering a single job number or remotely viadigital inputs. Each job is a set of operating conditions, includingsetpoints and alarms.

Non-Linear Output Curves Standard: Select either of two non-linearoutput curves for each control output.

Autotuning Makes Setup Simple: Use the Autotune feature to set upyour system quickly and easily. The CLS internal expert system tablefinds the correct PID parameters for your process.

Pulse Counter Input Standard: Use the pulse counter input for precisecontrol of motor or belt speed.


Introduction

Specifications

The following section contains specifications for inputs, outputs, theserial interface, system power requirements, environmentalspecifications, and the CLS physical dimensions.

Analog Inputs

Number of Control Loops: 4 (4CLS), 8 (8CLS), 16 (16CLS), plus onepulse loop.

Number of Analog Inputs: 4 (4CLS), 8 (8CLS), 16 (16CLS).

Input Switching: differential solid state MUX switching.

Input Sampling Rate:

4CLS: 6x/sec (167 ms) at 60 Hz; 5x/sec (200 ms) at 50 Hz.8CLS: 3x/sec (333 ms) at 60 Hz; 2.5x/sec (400 ms) at 50 Hz.16CLS:1.5x/sec (667 ms) at 60 Hz; 1.25x/sec (300 ms) at 50 Hz.

Analog Over Voltage Protection: +20 V referenced to digital ground.

Common Mode Rejection (CMR): For inputs that don't exceed +5 V,>60 dB DC to 1 kHz, and 120 dB at selected line frequency.

A/D Converter: Integrates voltage to frequency.

Input Range: -10 to +60 mV. Other ranges are available with scalingresistors.

Resolution: 0.006%, greater than 14 bits. (This is the internalmeasurement resolution, not the display resolution.)

Calibration: Automatic zero and full scale.


Introduction

Thermocouple Ranges and Resolution:

RTD Ranges and Resolution (4 and 8 CLS only):

T/C Break Detection: Pulse type for upscale break detection.

Milliamp inputs: 0-20 mA (3 ohms resistance) or 0-10 mA (6 ohmsresistance), with scaling resistors.

Voltage inputs: 0-12V, 0-10V, 0-5V, 0-1V, 0-500mV, 0-100 mV withscaling resistors.

Source Impedance: For 60 mV T/C, measurements are withinspecification with up to 500 ohms source resistance.

T/C Type

Range in °F Range in °C* Accuracy:

25°CAmbient

* Accuracy:0-50°C Full

Temp. Range

°C °C °F °C °F

J T/C -350 to 1400 -212 to 760 ±0.5 ±0.9 ±1.1 ±2.0

K T/C -450 to 2500 -268 to 1371 ±0.6 ±1.2 ±1.35 ±2.7

T T/C -450 to 750 -268 to 399 ±1.3 ±2.4 ±2.9 ±5.4

S T/C 0 to 3200 -18 to 1760 ±2.5 ±4.5 ±5.6 ±10.1

R T/C 0 to 3210 -18 to 1766 ±2.5 ±4.5 ±5.6 ±10.1

B T/C 150 to 3200 66 to 1760 ±6.6 ±12.0 ±14.9 ±27.0

E T/C -328 to 1448 -200 to 787

* True for 10% to 100% of span.

NameRange in

°FRange in

°CResolution

Measure-ment

Temp. In °C

Accuracy: 25°C

Ambient°C °F

Accuracy: 0-50°C Ambient°C °F

RTD1 -148.0 to 527.0

-100.0 to 275.0

0.023 °C 25 ±0.35 ±0.63 ±0.5 ±0.9

275 ±1 ±1.8 ±1.5 ±2.7

RTD2 -184 to 1544

-120 to 840 0.062 °C 25 ±0.9 ±1.62 ±2.8 ±5.04

840 ±1.1 ±1.98 ±4.3 ±7.74

RangeInput

Resistance

0-12 V 85 Kohms

0-10 V 50 Kohms

0-5 V 40 Kohms

0-1 V 7.4 Kohms

0-500 mV 6.2 Kohms

0-100 mV 1.2 Kohms


Introduction

Digital Inputs

Number: 8

Configuration: 8 selectable for output override, remote job selection.

Input Voltage Protection: Diodes to supply and common. Source mustlimit to 10 mA for override conditions.

Voltage Levels: <1.3V=Low; >3.7V=High (TTL).

Maximum Switch Resistance to Pull Input Low: 1 Kohms.

Minimum Switch Off Resistance: 11 Kohms.

User-Selectable Digital Outputs

Number: 34

Operation: Open collector output; On state sinks to logic common.Current ≤ 20 mA for 35 loads. Single load ≤ 40 mA. I total ≤ 700 mA.

Function: Selectable as PID control or alarm/control.

Number of PID Control Outputs per PID Loop: 2 (max)

PID Control Output Types: Time Proportioning, Distributed ZeroCrossing, SDAC, or On/Off—all independently selectable for eachoutput. Heat and cool control outputs can be individually disabled foruse as alarm outputs.

Time Proportioning Cycle Time: 1-255 seconds, programmable foreach output.

PID Control Action: Reverse (heat) or direct (cool), independentlyselectable for each output.

Off State Leakage Current: <.01 mA to DC common.

System Digital Outputs

System Digital Outputs: 1 Global Alarm, 1 CPU watchdog.

Operation: Open collector output; On state sinks to logic common.Current ≤ 20 mA for 35 loads. Single load ≤ 40 mA. I total ≤ 700 mA.


Introduction

Analog Outputs

The Watlow Anafaze Digital to Analog Converter (DAC) is an optionalmodule for the CLS. It lets you convert a Distributed Zero Crossingcontrol output signal to an analog process control signal. You canpurchase a 4-20 mAdc, 0-5 Vdc, and 0-10 Vdc versions of the DAC.

Watlow Anafaze also offers the Serial DAC for precision open-loopcontrol. 0-5 Vdc/4-20 mAdc jumper selectable.

Contact Watlow Anafaze for more information about the DAC andSerial DAC.


Introduction

Miscellaneous Specifications

Serial Interface

Type: RS-232 3 wire or RS-485 4 wire.

Isolation:

RS-232 None

RS-485 To EIA RS-485 Specification.

Baud Rate: 2400 or 9600, user selectable.

Error Check: BCC or CRC, user selectable.

Number of Controllers: 1 with RS-232 communications;

32 with RS-485 communications.

Protocol: Form of ANSI X3.28-1976 (D1, F1), compatible with AllenBradley PLC, full duplex.

System Power Requirements

Voltage: 12-24 Vdc

Input Current (no load): 300 mA max

Maximum Current Requirement: 610 mA. (If the reference voltage isexternally loaded, add 1 mA supply current for every 1 mA of load up toa maximum load of 100 mA. If using the +5V logic supply to powerdigital outputs, add 0.6 mA supply current for every 1 mA of load up toa maximum load of 350 mA. Therefore, the maximum currentrequirement is 300 +100 + (0.6 x 350) = 610 mA.)

Environmental Specifications

Storage Temperature: -20 to 60°C

Operating Temperature: 0 to 50°C

Humidity: 10 to 95% non-condensing.

Physical Dimensions

CLS: 1.75 lbs., 1.98" x 3.78" x 7.10" (.8 kg, 50 mm x 96 mm x 180mm.)

TB-18: 1.025" x 3.700" (2.57 cm x 9.29 cm)

TB-50: 3.2" x 3.4" (8.03 cm x 8.53 cm)


Introduction


Installation

InstallationThese installation instructions are written for non-technical users; if youare an electrician or you are technically proficient, they may seemsimple to you. Please at least skim all of the instructions, to make sureyou don't miss anything vital.

This section explains installation for the CLS only. If you are installinganother Watlow Anafaze product (such as an SDAC), see the manualshipped with it to learn how to install it.

These symbols are used throughout the rest of this manual:

DANGER

This symbol warns you about hazards to human life.

WARNING

This symbol warns you of possible damage to property orequipment.

NOTE

This symbol denotes information you must know in orderto proceed.


Installation

Precautions and Warnings

DANGER

Shut off power to your process before you install the CLS.High voltage may be present even when power is turnedoff! Reduce the danger of electric shock after installationby mounting the CLS in an enclosure that prevents per-sonal contact with electrical components.

The CLS measures input signals that are not normally ref-erenced to ground, so the CLS inputs and other signal linescan have high voltage present even when power is turnedoff--for example, if you inadvertently short a thermocoupleto the AC power line.

WARNING

During installation and wiring, place temporary coversover the housing slots and the rear of the CLS so dirt,pieces of wire, et cetera don't fall through the slots. Removethese covers after installation.

Install the CLS so the slots in the housing receive unre-stricted airflow after installation. Make sure that otherequipment does not block airflow to the housing slots.

Use #20 or #22 AWG wires and trim wire insulation to 1/4”(5 mm). Wire should fit inside the terminal with no barewire exposed, to prevent contact between wires and thegrounded case. Tin any stranded wire.

Support power, input and output cables to reduce strain onthe terminals and to prevent wire removal.

NOTEBe sure to select a panel location that leaves enough clear-ance to install and remove the CLS and its components.


Installation

Recommended Tools

Use these tools to install the CLS:

Panel Hole Cutters

Use any of the following tools to cut a hole of the appropriate size in thepanel.

• Jigsaw and metal file--for stainless steel and heavyweight panel doors.

• Greenlee 1/8 DIN rectangular punch (Greenlee part # 600-68), for most panel materials and thicknesses.

• Nibbler and metal file--for aluminum and lightweight panel doors.

Other Tools

You will also need these tools:

• Phillips head screwdriver.

• Flathead screwdriver for wiring.

• Multimeter.


Installation

CLS Mounting Procedure

NOTEMount the controller before you mount the terminal blockor do any wiring. The controller's placement affects place-ment and wiring considerations for the other componentsof your system.

Mounting Environment

Install the CLS in a location free from excessive (>50ºC) heat, dust, andunauthorized handling. The controller can mount in any panel materialup to 0.2" thick. (Make sure there is enough clearance for mountingbrackets and terminal blocks; the controller extends 6.2" behind thepanel face and the screw brackets extend 0.5" above and below it.)

Steps:

1. Cut a hole 3.630+0.020" long by 1.800+0.020" tall in the panel. This figure shows the mounting hole. (The figure is not a template.) Cut carefully; the 0.020" (0.5 mm) tolerances don't allow much room for error. Use a punch, nibbler, or jigsaw, and file the edges of the hole.

2. Insert the controller into the hole through the front of the panel.

3. Screw the top and bottom clips in place: insert the screw's lip into the cutout in the metal housing just behind the front panel. Tighten the screw.

4. If you expect much panel vibration, use a rear support for the CLS and its interconnecting cables.


Installation

TB-18 Mounting Instructions

These steps describe how to mount the TB-18 on the rear of the CLS.(Please follow these steps exactly, so you do not damage either theterminal block or the controller.)

1. Install the cable support on the underside of the CLS. The TB-18 was shipped to you in a plastic bag. The bag also contained a cable tie (the long plastic strip) and a cable tie mount (the square plastic piece with one sticky side).

a. Stick the cable tie mount to the underside of the CLS. Install it in a spot that won't block the vents.

b. Thread the cable tie through the hole in the cable tie mount. When you're finished wiring the outputs, it should look like this illustration.

2. Next, wire outputs to the terminal block. (For help, see Wiring Out-puts later in this chapter.) Route wires through the cable support, leaving about 9" of wire between the TB-18 and the support.

3. Gently slide the female part of the terminal block into the 50-pin header on the rear of the controller, as shown here.

WARNING

Do not connect power to the CLS now. Test the unit first, asexplained in the Power Wiring and Controller Test section.


Installation

TB-50 Mounting Instructions

These steps tell you how to mount the TB-50. (Please follow these stepsexactly, so you don’t damage the terminal block, the ribbon cable, or thecontroller.)

1. Choose a mounting location. Be sure there is enough clearance to install and remove the TB-50; it measures 3.4" long X 3.2" wide X 1.27" tall.

2. Watlow Anafaze shipped the TB-50 to you in an antistatic bag. Make sure these parts are also in the bag:

•Five plastic standoffs.

•Five 6-32 screws.

•Five cable tie wraps.

•One 50-pin ribbon cable.

•Five ribbon cable clamps.

3. Snap four of the plastic standoffs into the four mounting holes on the TB-50.

There are also four smaller holes on the terminal board, as shown here. These holes are for the cable tie wraps--the plastic standoffs won’t fit them. You’ll use these holes to secure wiring to the termi-nal block. (See Wiring Outputs in this chapter for help installing cable tie wraps.)

1

12345678910111213A

25242322212019181716151413B

26272829303132333435363738A

50494847464544434241403938BB

B

B

B

A

A

A

A

Holes labeled "A"are m ounting holes.Holes labeled "B"are tie wrap holes.


Installation

4. Place the TB-50 where you will mount it and use a pencil to trace around the standoffs.

5. Drill and tap #6-32 holes in the locations you marked.

6. Place the TB-50 where you will mount it. Insert the #6 screws in the standoffs and tighten them.

NOTE

Save the cable tie wraps, ribbon cable, and ribbon cableclamps. You’ll use them when you wire outputs to the TB-50 and when you connect the ribbon cable.

WARNING

Do not connect power to the CLS now. Test the unit first, asexplained in the Power Wiring and Controller Test section.


Installation

General Wiring Recommendations

Use the cables below or their equivalent. For best results, useappropriate materials, proper installation techniques and the correctequipment. For example, choose wire type by function, installationrequirements, and the likelihood of mechanical or electrical problemsat your installation.

WARNING

Never wire bundles of low power controller circuits next tobundles of high power AC wiring. Instead, physically sepa-rate high power circuits from the controller. If possible,install high voltage AC power circuits in a separate panel.

• Use stranded wire. Solid wire is used for fixed service; it makes intermittent connections when you move it for maintenance.

• Use #20 or #22 AWG wire. Larger or smaller sizes may be difficult to install, may break easily, or may cause intermittent connections.

• Use shielded wire. (The electrical shield helps protect the CLS from electrical noise.) Connect one end of the input wiring shield to the CLS panel's 120 Vac panel ground, and connect one end of the out-put wiring shield to the CLS panel's 120 Vac panel ground. (Some installations may require a different shield configuration. Contact Watlow Anafaze for more information if these instructions do not apply to your system.)

For more noise suppression measures, see Noise Suppression.

Function MFR P/NNo. of Wires

AWG

Analog inputs Belden #9154Belden #8451

22

2022

RTD Inputs (4 & 8 CLS) Belden #8772Belden #9770

33

2022

T/C Inputs T/C Ext. Wire 2 20

Digital PID outputs and Dig-ital I/O

Belden #9539Belden #9542Ribbon Cable

92050

2424

Computer Communication: RS232 or RS485

Belden #9729Belden #9730Belden #9842Belden #9843

4646

24242424


Installation

Grounding

Connect the CLS chassis to an external ground at only one point, toavoid ground loops that can cause instrument errors or malfunctions.Since the CLS uses a non-isolated measurement system, it has thefollowing connections to power supply common:

• Analog common TB1 pins 5, 6, 11, & 12

• Reference common, TB1 pin 17

• Communications ground (TB1 pins 23 & 24) if using RS-232

• Power supply ground, TB2 pin 2

• Control common (TB-18 pin 2; TB-50 pin 3 and 4)

Watlow Anafaze strongly recommends that you:

• Do not connect any one of these pins to earth ground. Do not tie them together externally.

• Isolate outputs through solid state relays, where possible.

• Isolate RTDs or “bridge” type inputs from ground, if used.

• Isolate digital inputs from ground through solid state relays. If you can't do that, then make sure the digital input is the only place that one of the above pins connects to ground.

• If you are using RS-232 from an un-isolated host, don't connect any other power common point to earth ground.


Installation

Thermocouple Wiring

Use 18 or 20 AWG thermocouple (T/C) extension wire for all the T/Cinputs.

NOTEMost thermocouple wire is solid unshielded wire. Useshielded wire if required at your installation; ground oneend only.

WARNING

The CLS uses a floating ground system. Therefore:

Isolate input devices or host computers connected throughcommunications cables (like RS-232) from earth ground.

Use ungrounded thermocouples with the thermocouplesheath electrically connected to earth ground.

Use optically isolated RS-232 devices to isolate earthgrounded host computers from CLSs.

When you use grounded T/Cs, tie the thermocouple shieldsto a common earth ground in one place. Otherwise anycommon mode voltages that exceed 5 volts may causeincorrect readings or damage to the controller.

WARNING

The 16CLS has single ended inputs, offering little protec-tion from common mode voltage sources. ThereforeWatlow Anafaze highly recommends that you useungrounded thermocouples with the external thermocou-ple sheath electrically connected to earth ground.

You can use 400 to 500' of thermocouple extension wire, depending onwire type and wire size, and keep to accuracy and source impedancespecifications. Be sure to install thermocouple wiring in a separateconduit away from AC power (the 120 Vac control supply) and highpower (240 Vac or higher) wiring.

Input Wiring

Use multicolored stranded shielded cable for analog inputs. WatlowAnafaze recommends that you use #20 AWG wire. (If the sensormanufacturer requires it, you can also use #22 or #24 AWG wiring.)Most inputs use a shielded twisted pair; some require a 3 wire input.


Installation

Output Wiring

Use multicolored stranded shielded cable for analog outputs (if youhave installed an SDAC) and PID digital outputs connected to panelmount SSRs. Analog outputs generally use a twisted pair, while digitaloutputs have 9-20 conductors, depending on wiring technique.

For instructions on using the cable tie wraps included in the TB-50’spackaging, see the Wiring Outputs section.

Communications Wiring

Large systems can pull in an extra pair to the computer communicationswiring. The extra pair services a sound power phone system forcommunications between the Watlow Anafaze controller and acomputer.

If you choose this option for maintenance, calibration checking, etcetera, Watlow Anafaze recommends a David Clark #H5030 system.


Installation

Wiring: Noise Suppression

If the CLS's outputs control dry contact electromechanical relays withinductive loads--like alarm horns and motor starters--you may getElectro-magnetic Interference (EMI, or “noise”) The following sectionexplains how to avoid noise problems; read it before you wire the CLS.

Symptoms of RFI/EMI

If your controller displays the following symptoms, suspect EMI.

• The CLS's display blanks out and then reenergizes as if power had been turned off for a moment.

• The process value does not display correctly.

EMI may also damage the digital output circuit--so digital outputs willnot energize. If the digital output circuit is damaged, return thecontroller to Watlow Anafaze for repair.

Avoiding Noise Problems

To avoid noise problems:

Where possible, use solid state relays (SSRs) instead ofelectromechanical (EM) relays. If you must use EM relays, try to avoidmounting them in the same panel as the CLS equipment.

Separate the 120 Vac power leads from the low level input and outputleads connected to the CLS. Don't run the digital output or PID controloutput leads in bundles with 120 Vac wires. (Never run input leads inbundles with high power leads. See the General Wiring section.)

If you must use EM relays and you must place them in a panel with CLSequipment, use a .01 microfarad capacitor rated at 1000 Vac (or higher)in series with a 47 ohm, ½ watt resistor across the NO contacts of therelay load. This network is known as an arc suppressor or snubbernetwork.

You can use other voltage suppression devices, but they are not usuallyrequired. For instance, you can place a metal oxide varistor (MOV)rated at 130 Vac for 120 Vac control circuits across the load, whichlimits the peak AC voltage to about 180 Vac (Watlow Anafaze P/N 26-130210-00). You can also place a transorb (back to back zener diodes)across the digital output, which limits the digital output loop to 5 Vdc.(All the parts mentioned here are available from Watlow Anafaze).

The above steps will eliminate most noise problems. If you have furtherproblems or questions, please contact Watlow Anafaze.


Installation

General Wiring

The following sections explain how to test your installation before youconnect power to it and how to connect inputs and outputs to it.

Power Wiring and Controller Test

When you have installed each component of the controller and the TB-50 (if used), use this checklist to connect them. These instructions arewritten so that non-electricians can understand them. If you are anexperienced electrician, they may seem elementary to you. If so, feelfree to skim them.

Connecting Power and TB-50 to CLS

1. Remove the temporary covers on the CLS housing.

2. The plug-in power supply, included with your controller, has two bare wires. The + side connects to TB2-1, and the - side to TB2-2. As a precaution, you should check the polarity of the wires with a multimeter (color coding of the wires is not always reliable with older power supplies). Do not turn on the AC power yet.

3. Connect the ribbon cable to the controller, as shown here. Plug it in so the red stripe is on the left side as you face the back of the con-troller.

4. Connect the ribbon cable to the TB-50. The cable is keyed, so you cannot insert it backwards.

WARNING

Do not turn on the AC power yet. Test the connections first,as explained in the Connections Test section below.

Excessive voltage to the CLS will damage it, and you willneed to return it to Watlow Anafaze for repair. If you useyour own power supply, read the next section completelyand follow its instructions before you apply power to theCLS.


Installation

Connections Test

Again, follow these instructions if you have purchased your own powersupply, or if you are using a Watlow Anafaze power supply, you don’tneed to perform this test.

1. Unscrew the two screws on the sides of the CLS front panel.

2. Gently slide the electronics assembly out of the case. You have now removed the parts of the CLS which will be damaged by excess voltage, so plug in the transformer power supply and use a voltme-ter to check voltages:

3. Touch the meter Common lead to the back Terminal Block 2 (TB2) terminal 2 on the CLS. The voltage on TB2 terminal 1 should then be +12 to 24 Vdc.

4. If the voltages are within the limits described above,

a. Turn off power.

b. Slide the electronics assembly back into the processor mod-ule’s casing.

c. Reinsert screws into the screw holes on the casing and lighten them.

d. Turn the power back on. The CLS display should light up, and after about a second the Bar Graph display should appear.

If you have not connected analog inputs yet, the CLS may dis-play a “T/C Break” alarm message for each channel. This is normal; to clear the alarm messages, press ALARM ACK once for each alarm message.


Installation

Outputs

NOTEYour CLS is shipped with heat outputs enabled and cooloutputs disabled. You can disable any PID output and use itfor other digital output functions.

All digital outputs and PID outputs are sink outputs referenced to the5Vdc supply. These outputs are Low (pulled to common) when they areOn.

All digital inputs are Transistor-Transistor Logic (TTL) level inputsreferenced to control common.

The control outputs are located on the 50 pin header which connects tothe TB-18 or TB-50 pin flat ribbon cable. This section explains how towire and configure them.

Wiring Outputs

The CLS provides dual PID control outputs for each loop. The digitaloutputs sink current from a load connected to the CLS's internal powersupply or from an external power supply referenced to CLS ground.

• If you use an external power supply, do not exceed +12 volts.

• If you tie the external load to ground, or if you cannot connect it as shown below, then use a solid state relay.

• If you connect an external supply to earth or equipment ground, use solid state relays to avoid ground currents. (Ground currents may degrade analog measurements in the CLS).

The outputs conduct current when they are “True”. The maximumcurrent sink capability is 20 mA (when all outputs are used). Theycannot “source” current to a ground load


Installation


Installation

Using the Cable Tie Wraps

When you have wired outputs to the TB-50, use the cable tie wrapsshipped with it. This diagram shows the cable tie wrap holes.

Each row of terminals has a cable tie wrap hole at one end. Thread thecable tie wrap through the cable tie wrap hole. Then wrap the cable tiewrap around the wires attached to that terminal block.

Configuring Outputs

• You can enable or disable the control outputs. The default setting is heat outputs enabled, cool outputs disabled.

• You can program each control output individually for On/Off, TP, SDAC, or DZC control.

• You can individually program each control output for direct or reverse action.

1

12345678910111213A

25242322212019181716151413B

26272829303132333435363738A

50494847464544434241403938BB

B

B

B

A

A

A

A

Holes labeled "A"are m ounting holes.Holes labeled "B"are tie wrap holes.


Installation

PID Control and Alarm Output Connections

Typical digital control outputs use external optically isolated solid-staterelays (SSRs). The SSRs use a 3 to 32 Vdc input for control, and youcan size them to switch up to 100 amps at 480 Vac. For larger currents,you can use these optically isolated relays to drive contactors. You canalso use Silicon Control Rectifiers (SCRs) and an SDAC for phase-angle fired control.

NOTEControl outputs are SINK outputs. They are Low when theoutput is On. Connect them to the negative side of SolidState Relays.

The figure below shows sample heat/cool and alarm output connections.

Watchdog Timer

The CLS watchdog timer constantly monitors the CLS microprocessor.It is a sink output located on TB-18 terminal #3, or on TB-50 terminal#6. (Do not exceed the 10 mAdc rating for the watchdog timer.) Itsoutput is Low (on) when the microprocessor is operating; when it stopsoperating, the output goes High (off), which de-energizes the SSR.

This figure shows the recommended circuit for the watchdog timeroutput.


Installation

TB-18 Connections

This table shows TB-18 connections to the 4CLS and the 8CLS.

*If you install a Watlow Anafaze Serial DAC (SDAC), the CLS usesdigital output #34 for a clock line. You cannot use output #34 foranything else when you have an SDAC installed.

PIN FunctionPID Output

4CLS 8CLS

1 +5 Vdc

2 Digital ground

3 Watchdog timer

4 Global alarm

5 Digital output 1 Loop 1 heat Loop 1 heat




9 Digital output 5 Pulse loop heat Loop 5 heat

10 Digital output 6 Loop 1 cool Loop 6 heat



13 Digital output 9 Loop 4 cool Pulse loop heat

14 Digital output 10 Pulse loop cool Loop 1 cool

15 Digital output 34* SDAC clock SDAC clock

16 Digital input 1

17 Digital input 2

18 Digital input 3/Pulse input


Installation

TB-50 Connections

4 and 8 CLS TB-50 Connections.

If you install a Watlow Anafaze Serial Digital to Analog Converter(SDAC), the CLS uses digital output #34 for a clock line. You cannotuse output #34 for anything else when you have an SDAC installed.

* The indicated outputs are dedicated to PID (or control) when enabledin the loop setup. If one or both of a loop’s outputs are disabled, thecorresponding digital outputs become available for alarms or ramp/soakevents.

Pin FunctionPID Output*

8CLS 4CLSPin Function

PID Output*8CLS 4CLS

1 +5 Vdc 2 +5 Vdc

3 CTRL COM 4 CTRL COM

5 Not Used 6 Watchdog Timer

7 Pulse Input 8 Global Alarm

9 DIG output 1 Loop 1 heat Loop 1 heat 10 DIG output 34*

11 DIG output 2 Loop 2 heat Loop 2 heat 12 DIG output 33



17 DIG output 5 Loop 5 heat Pulse loop heat

18 DIG output 30

19 DIG output 6 Loop 6 heat Loop 1 cool 20 DIG output 29



25 DIG output 9 Pulse loop heat

Loop 4 cool 26 DIG output 26

27 DIG output 10 Loop 1 cool Pulse loop cool

28 DIG output 25

29 DIG output 11 Loop 2 cool 30 DIG output 24






41 DIG output 17 Loop 8 cool 42 DIG output 18 Pulse loop cool

43 DIG input 1 44 DIG input 2





Installation

16 CLS TB-50 Connections.

If you install a Watlow Anafaze Serial digital to Analog Converter(SDAC), the CLS uses digital output #34 for a clock line. You cannotuse output #34 for anything else when you have an SDAC installed.

* The indicated outputs are dedicated to PID (or control) when enabledin the loop setup. If one or both of a loop’s outputs are disabled, thecorresponding digital outputs become available for alarms or ramp/soakevents.

Pin Function PID Output* Pin Function PID Output*

1 +5 Vdc 2 +5 Vdc

3 Digital Ground 4 Digital Ground

5 Not Used 6 Watchdog Timer

7 Pulse Input 8 Global Alarm

9 DIG output 1 Loop 1 heat 10 DIG output 34* Pulse loop cool

11 DIG output 2 Loop 2 heat 12 DIG output 33 Loop 16 cool















41 DIG output 17 Pulse loop heat 42 DIG output 18 Loop 1 cool






Installation

Inputs

This section covers input scaling and input installation for all inputtypes, including thermocouples, RTDs, current inputs, and voltageinputs.

Input Scaling

The CLS analog input circuitry accepts any mix of thermocouples, 2 or3 wire RTD inputs, current inputs, and voltage inputs. You can directlyconnect the following inputs:

• J, K, T, S, R, B, and E thermocouples.

• Linear inputs with ranges between -10 and 60 mV.

Other inputs require custom scaling resistors. If you didn't order yourunit with the appropriate resistors, you have the following options:

• Watlow Anafaze can install scaling resistors on your unit for a nomi-nal fee.

• Watlow Anafaze can supply a scaling resistor kit that a qualified technician can use to install scaling resistors.

WARNING

A qualified technician can install scaling resistors in theCLS. However, damage to the CLS due to improper resis-tor installation is not covered under warranty, and repairscan be expensive. If you have any doubts about your abilityto install scaling resistors, send your CLS to WatlowAnafaze for resistor installation.


Installation

4 and 8 CLS Scaling Values

• For RTD1 inputs, RA and RB are a matched pair (RP). Their match-ing tolerance is 0.02% (2 ppm/ºC) and their absolute tolerance is

0.1% (10 ppm/ºC). RC has 0.05% tolerance.

• For RTD2 inputs, use 0.05% tolerance resistors.

• For linear mVdc, Vdc, and mAdc ranges, use 0.1% tolerance resis-tors. Higher tolerances may cause significant errors. Correct any errors due to resistor tolerance with the CLS's built-in linear scaling. You can also install other components (like capacitors) for signal conditioning; please consult Watlow Anafaze for more information.

NOTEWhen adding your own scaling resisters to the 4 and 8 CLS,the shorting pads of the RC must be cut before installing tothe bottom of the PC board.

A COM

A -RC

IN -

IN +A +

RD

RB

ToCLSCircuitry

AnalogInputTerminal

Internal

RA

+5 Vdc Reference

C .47 uF

C .47 uF

(RTD/Thermister)

( Voltage/Current)RC


Installation

The next table shows scaling resistor values.

The following tables show the location of RA, RB, RC and RD on theanalog input boards of the 4CLS and the 8CLS. (The analog input boardis the upper board of the two-board set.)

Input Range RA RB RC RD

All T/C, 0-60 mV DC Jumper

RTD 1: -100.0 to 275.0ºC

RTD 2: -120 to 840ºC

10.0 Kohms25.0 Kohms

10.0 Kohms25.0 Kohms

80 ohms100 ohms

0-10 mA DC0-20 mA DC

JumperJumper

6.0 ohms3.0 ohms

0-100 mV0-500 mV

499 ohms5.49 Kohms

750 ohms750 ohms

0-1 VDC0-5 VDC0-10 VDC0-12 VDC

6.91 Kohms39.2 Kohms49.9 Kohms84.5 Kohms

422.0 ohms475.0 ohms301.0 ohms422.0 ohms


Installation

4CLS: Voltage/Current Inputs

8CLS: Voltage/Current Inputs

4CLS: RTD/Thermister Inputs

8CLS: RTD/Thermister Inputs

Place resistors RA, RB and RD in the resistor pair locations this way:

A wire trace on the printed circuit board jumpers the RC position. Whenyou place a resistor in the RC position, cut the wire trace that connectsthe two resistor terminals.

Loop # RC RD

1 58 RP1

2 56 RP2

3 54 RP3

4 52 RP4

Loop RC RD Loop RC RD

1 58 RP1 5 50 RP5

2 56 RP2 6 48 RP6

3 54 RP3 7 46 RP7

4 52 RP4 8 44 RP8

Loop # RA/RB RC

1 RP1 57

2 RP2 55

3 RP3 53

4 RP4 51

Loop RA/RB RC Loop RA/RB RC

1 RP1 57 5 RP5 49

2 RP2 55 6 RP6 47

3 RP3 53 7 RP7 45

4 RP4 51 8 RP8 43


Installation

16 CLS Scaling Values

For linear mVdc, Vdc, and mAdc ranges, use 0.1% tolerance resistors.Higher tolerances may cause significant errors. Correct any errors dueto resistor tolerance with the CLS’ built-in linear scaling. You can alsoinstall other components (like capacitors) for signal conditioning; pleaseconsult Watlow Anafaze for more information.

The next table shows scaling resistor values.

The next table shows the location of RC and RD on the analog inputboard. (The analog input board is the upper board of the two-board set.)

A wire trace on the printed circuit board jumpers the RC position. Whenyou place a resistor in the RC position, cut the wire trace that connectsthe two resistor terminals.

Input Range RC RD

All T/C, 0-60 mV DC Jumper

0-10 mA DC0-20 mA DC

JumperJumper

6.0 ohms3.0 ohms

0-100 mV0-500 mV

499 ohms5.49 Kohms

750 ohms750 ohms

0-1 VDC0-5 VDC0-10 VDC0-12 VDC

6.91 Kohms39.2 Kohms49.9 Kohms84.5 Kohms

422.0 ohms475.0 ohms301.0 ohms422.0 ohms

Loop # RC RD Loop # RC RD

1 R58 R42 9 R57 R41

2 R56 R40 10 R55 R39

3 R54 R38 11 R53 R37

4 R52 R36 12 R51 R35

5 R50 R34 13 R49 R33

6 R48 R32 14 R47 R31

7 R46 R30 15 R45 R29

8 R44 R28 16 R43 R27

Analog

IN +

RD

CLS MeasurementCircuitry

AnalogInputTerminals

RC

Common

IN +


Installation

Scaling and Calibration

The CLS provides offset calibration for thermocouple, RTD, and otherfixed ranges, and offset and span (gain) calibration for linear and pulseinputs. (Offset and span calibration convert linear analog inputs intoengineering units using the Mx+B function.)

In order to scale linear input signals, you must:

1. Install appropriate scaling resistors. (Contact Watlow Anafaze's Customer Service Department for more information about install-ing scaling resistors.)

2. Select the display format. The smallest possible range is -.9999 to +3.0000; the largest possible range is -9999 to 30000.

3. Enter the appropriate scaling values for your process.

For more information about input scaling and input offset, see SetupLoop Inputs in Chapter 4: Setup.

T/C Inputs

WARNING

The CLS uses a floating ground system. Therefore:

Isolate input devices or host computers connected throughcommunications cables (like RS-232) from earth ground.

Use ungrounded thermocouples with the thermocouplesheath electrically connected to earth ground.

Use optically isolated RS-232 devices to isolate earthgrounded host computers from the CLS.

When you use grounded T/Cs, tie the thermocouple shieldsto a common earth ground in one place. Otherwise anycommon mode voltages that exceed 5 volts may causeincorrect readings or damage to the controller.

WARNING

The 16CLS has single ended inputs, offering little protec-tion from common mode voltage sources. ThereforeWatlow Anafaze highly recommend that you useungrounded thermocouples with the external thermocou-ple sheath electrically connected to earth ground.


Installation

You can connect J, K, T, S, R, B, and E thermocouples directly to theCLS. Watlow Anafaze provides standard linearization and cold junctioncompensation for these thermocouple types. (Other thermocouple typesrequire custom linearization; please contact Watlow Anafaze for moreinformation about them.)

Connecting Thermocouples

Connect the positive T/C lead to the In+ terminal. Connect the negativeT/C lead to the TB1 In- (4 or 8CLS) or analog common 16CLS)(terminal. A typical thermocouple connection is shown in the figurebelow.

• Use 20 gauge thermocouple extension wire for all thermocouple inputs.

• If you use shielded wire, tie it to panel ground or to ground at the measurement end.

RTD Inputs (4 and 8 CLS only)

The standard industrial RTD is an 100-ohm, 3-wire platinum assemblyas shown in the figure below. Watlow Anafaze highly recommends thatyou use the 3-wire RTD to prevent reading errors due to cableresistance.

• If you order an RTD1 or RTD2 configuration, Watlow Anafaze will configure your CLS for the standard 3-wire RTD.

• If you must use a 4-wire RTD, leave the fourth wire unconnected.

Watlow Anafaze offers 2 standard DIN 385 curve RTD input ranges, asshown here:

RTD Ranges in Degrees

Name Temp. Range in ºF

Temp. Range in ºC

Resolution Measurement Temperature

Error @ 25 ºC Ambient

Error @ 0-50 ºC Ambient

RTD1 -148.0 to 527.0 ºF

-100.0 to 275.0 ºC

0.023 ºC 25 ºC ±0.35 ºC ±0.5 ºC

275 ºC ±1 ºC ±1.5 ºC

RTD2 -184 to 1544 ºF

-120 to 840 ºC

0.062 ºC 25 ºC ±0.9 ºC ±2.8 ºC

840 ºC ±1.1 ºC ±4.3 ºC

White

RedType J T/C

IN +

IN –

CaseShield (if present)

Frame Ground


Installation

Below is a typical RTD.

Current Inputs

To connect current (milliamp) inputs, install resistors that convert themilliamp input to a voltage. Watlow Anafaze offers resistors for 0-20mA and 0-10 mA current inputs.

Voltage Inputs

• Connect the + side of the voltage input to the In+ terminal.

• Connect the - side of the input to the In- terminal for the 4 and 8CLS, or analog common for the 16CLS. The 0voltage input range is -10 to 60 mV.

• Scale signals larger than 60 mV with scaling resistors that make full scale input 60 mV. (For more information, see the Input Scaling sec-tion.)

The figures below show typical voltage input.

16CLS

4 and 8 CLS

In+

Back Terminal BlockConnections

AnalogCommon

In-

In+



AnalogCommon

In+

In -


Installation

Unused Inputs

Set the input type for unused inputs to “SKIP” to avoid the default T/Cbreak alarms. (See Input Type in Chapter 4: Setup for information onsetting the input type.)

Back Terminal Block Connections

Wire inputs to the back terminal block as shown below.

4CLS

8CLS

16 CLS


Installation

Serial Communications

The CLS is factory-configured for RS-232 communications. However,the communications are jumper-selectable, so you can switch betweenRS-232 and RS-485. (See Configuring Communications below.) Youcan also order a communications cable from Watlow Anafaze or makeyour own cable.

RS-232 Interface

With RS-232 communications, you can connect the CLS directly to theserial communications connector on an IBM-PC or compatiblecomputer. (PC-compatible computers typically use RS-232communications.) The RS-232 interface is a standard three-wireinterface. See the table below for connection information. (Somecomputers reverse transmit (TX) and receive (RX), so check yourcomputer manual to verify your connections.)

You can use either RS-232 or RS-485 communications in thesesituations:

• When you are using local communications (up to 50 feet).

• When you are using a single CLS.

If you are using RS-232 communications with grounded thermocouples,use an optical isolator between the controller and the computer.

This table shows RS-232 connections for 25-pin and 9-pin connectors.

RS-485 Interface

• If you use more than one CLS, you must use RS-485 communica-tions.

• If you have connected the CLS to a computer more than 50 feet away, Watlow Anafaze recommends that you use RS-485 communi-cations.

If you use RS-485 communications, attach an optically isolated RS-232to RS-485 converter to the computer. You can use an internal convertercard or an external plug-in converter.

DB 25 Connector

DB 9 Connector

CLS Back TBWatlow Anafaze

Cable

RX Pin 3 RX Pin 2 TX Pin 26 White

TX Pin 2 TX Pin 3 RX Pin 25 Red

GND Pin 7 GND Pin 5 GND Pin 23 Black


Installation

The diagram on the next page shows the recommended system hookup.To avoid ground loops, it uses an optically isolated RS-232 to RS-485converter at the host computer. The system is powered from the CLS'spower source or from a secure, isolated supply.

Wire equipment in a single “daisy chain” using twisted shielded pairsfor the RS-485 cables. Don't use “octopus connections” or “spurs”.

CLS

CLS

OpticallyIsolatedConverter

HostComputer

Fifth Wire

Optional Capacitor

PowerSupply

PowerSupply

PowerSupply

-+

+ -

+-


Installation

Use a 200 ohm terminating resistor on the RX line of the last controllerin the system. (If you have only one controller, it is the last controller inthe system.) Use jumper JU1 to select the terminating resistor; place itin B position for termination and A position for non-termination.

NOTE

Connect the shields to earth ground only at the computeror other 485 interface. Do not connect the shield to thecontroller. If you connect RS-485 communications and they do notfunction properly, or if you have measurement problemswhen communications lines are connected, request addi-tional technical information from the Watlow AnafazeCustomer Service Department.


Installation

Configuring Communications

Your controller is shipped configured for RS-232. To switch betweenRS-232 and RS-485, change the jumpers as shown here.

You'll need tweezers and a Phillips head screwdriver to switch betweenRS-232 and RS-485. Follow these steps:

1. Power down the unit.

2. Remove the controller's metal casing. If you haven't removed the casing before, please don't try to figure it out yourself; see Chang-ing the PROM in the Troubleshooting section for step-by-step instructions.

3. Find jumpers JU2, JU3, JU4, and JU5 (above).

4. (This part of the explanation assumes that you're changing the com-munications from RS-232 to RS-485. If you're not, follow the next two steps but move the jumpers from the B position to the A posi-tion.) Use tweezers to carefully grasp the jumpers and gently slide them off the pins.

5. Use tweezers to gently slide the jumpers onto the B pins. Move jumpers JU2, JU3, JU4, and JU5 to the B position, as shown above.

6. If you have changed the controller to 485 communications, put the 200 ohm terminating resistor on the RX line of the last controller in the system. (If you're only using one controller, it's the last control-ler in the system.) Place jumper JU1 in the B position . All other controllers in the system should have JU1 in the A position.

7. Put the casing back on. If you haven't removed or reinstalled the CLS's casing before, see Chapter 7: Troubleshooting for instruc-tions.


Installation

Recommended Wire Gauges

Watlow Anafaze recommends the following maximum distances andwire gauges:

You may wish to use a shield, depending on your noise environment andgrounding problems. The above cables are shielded.

NOTE

These recommendations are conservative, to ensure thatyour controller will operate reliably. Expect satisfactoryperformance even if you must deviate slightly from adesign specification.

Distance Wire GaugeRecommended

Cable

4000 ft. 24 AWG Belden #9729Belden #9842

6000 ft. 22 AWG Belden #9184


Installation


Using the CLS

Using the CLSIntroduction

This chapter will show you how to use the CLS from the front panel. (Ifyou are using ANASOFT or AnaWin, please see the related User'sGuide.) The next diagram shows how to reach the operator menus fromSingle Loop display. (To change global parameters, loop inputs, controlparameters, outputs, and alarms from the setup menus, you must enter aspecial sequence of keys. To learn how, see the next chapter: setup.)


Using the CLS

Front Panel

The front panel provides a convenient interface with the controller. Youcan program and operate the CLS with the front panel keys shownbelow, or you can use ANASOFT, a program designed specifically forWatlow Anafaze controllers.

Front Panel Keys

Yes/Up

Press Yes to

• Select a menu.

• Answer Yes to Yes/No questions.

• Increase a number or choice you're editing.

No/Down

Press No to

• Skip a menu you don't want to edit, when the prompt is blinking.

• Answer No to Yes/No prompts.

• Decrease a number or choice when editing.

• Perform a No Key Reset.


Using the CLS

WARNING

Pressing the No key on power up will clear the RAM mem-ory and reinitialize the CLS' factory default values.

To do a No Key Reset, power down the controller, press and hold the Nokey, and power up the controller while holding the No key. A No KeyReset is appropriate:

• After you change the EPROM. (See Chapter 6: Troubleshooting.)

• In some cases when troubleshooting (see Chapter 6: Troubleshoot-ing).

• When you install the controller.

Back

The Back key works like an “escape key”. Press it to:

• Abort editing.

• Return to a previous menu.

• Switch between Bar Graph, Single Loop, and Job Control displays.

Enter

Press Enter to:

• Store data or menu choices after editing and go on to the next menu.

• Start scanning mode (if pressed twice).

Change SP

• Press this key to change the loop setpoint.

Man/Auto

Press the Man/Auto key to:

• Toggle a loop between manual and automatic control.

• Adjust the output power level of loops in Manual control.

• Automatically tune a loop.


Using the CLS

Ramp/Soak

If Ramp/Soak is installed on your controller, press the Ramp/Soak keyto:

• Assign a ramp/soak profile to the current loop.

• Perform operations on an assigned profile.

• See the status of a running profile.

NOTE

Your CLS may not have the Ramp/Soak feature. If it does not,then the Ramp/Soak key will not operate. If you press theRamp/Soak key, you'll see the following message:

Alarm Ack

Press Alarm Ack to acknowledge an alarm condition and reset theglobal alarm digital output.

LOOP PROCESS UNITS

ALARM SETPOINT STATUS OUT%

OPTIONUNAVAILABLE


Using the CLS

Displays

The next section discusses the CLS' main displays--Bar Graph, SingleLoop, and Job displays.

Bar Graph Display

On power up, the CLS displays general symbolic information for allfour primary loops. This display is called Bar Graph mode. The diagrambelow shows the symbols used in Bar Graph mode.

The next table explains the symbols you see on the top line of the BarGraph display. These symbols appear when the controller is in dualoutput mode (heat and cool outputs enabled) and single output mode(heat or cool outputs enabled, but not both).

Symbol Symbol’s Meaning

< Loop is in low process or low deviation alarm.

> Loop is in high process or high deviation alarm.

Loop is above setpoint. If you enable the high or low devia-tion alarm, this symbol is scaled to it. If you don’t enable these alarms, these symbols are scaled to the setpoint +5% of the sensor’s range.

Loop is at setpoint. If you enable the high or low deviation alarm, this symbol is scaled to it. If you don’t enable these alarms, these symbols are scaled to the setpoint +5% of the sensor’s range.

Loop is below setpoint. If you enable the high or low devia-tion alarm, this symbol is scaled to it. If you don’t enable these alarms, these symbols are scaled to the setpoint +5% of the sensor’s range.

(Blank) Loop is set to SKIP.

F Sensor has failed.

LOOP PROCESS UNITS


01 08 AAAA MAMA

Alarm Symbol

Loop Numberor Name

Loop Status


Using the CLS

The next table explains the symbols you see on the bottom line of BarGraph display. These symbols appear when the controller is in both dualoutput mode and single output mode. If an alarm occurs, the controllerautomatically switches to Single Loop display and shows an alarm code.

Navigating in Bar Graph Display

• Press Yes (up) or No (down) to see Bar Graph Display for the Pulse Input loop.

• Press Enter twice to start Bar Graph scanning mode. In scanning mode, the controller alternately displays the first four loops and then the pulse input loop for three seconds each.

• Press any key to stop scanning mode.

• From Bar Graph Display, press Back once to go to Single Loop dis-play.

Single Loop Display

Single Loop display (below) shows detailed information for only oneloop. If the heat and cool outputs are enabled, Single Loop display lookslike this:

The control status indicator shows HEAT or COOL if the loop is inautomatic control, and MAN or TUNE if the loop is in manual control.

Symbol Symbol’s Meaning

M One or both outputs enabled. Loop is in manual control.

A Only one output (heat or cool, but not both) is enabled. Loop is in automatic control.

T Loop is in Autotune mode.

HT

Both heat and cool outputs are enabled. Loop is in Automatic control and heating.

CL

Both heat and cool outputs are enabled. Loop is in Automatic control and cooling.

LOOP PROCESS UNITS


02 160 ºF180 AUTO 100

EngineeringUnitsOutputpercentage

Control Status

Setpoint

Loop Numberor Name

Process Variable


Using the CLS

If only one output is enabled (heat or cool, but not both), Single Loopdisplay looks like this:

From Single Loop Display,

• Press Yes to go to the next loop.

• Press No to go to the previous loop.

• Press the Back key once to go to Job display (if enabled) or Bar Graph display.

• Press Enter twice to start Single Loop Scanning display. (The Single Loop Scanning Display shows information for each loop in sequence. Data for each loop displays for one second.)

• Press any key to stop scanning mode.

LOOP PROCESS UNITS


02 160 ºF 0 180 AUTO 100

Control Status

Output PercentageHeat

Output Percentage Cool

Engineering UnitsProcess Variable

Setpoint

Loop Numberor Name


Using the CLS

Alarms

If an alarm occurs, a two-character alarm code appears in the lower leftcorner of the display (below). If a Failed Sensor alarm occurs, thecontroller also displays a short alarm message.

These alarm codes and messages are shown in the table below.

Acknowledging an Alarm

Press Alarm Ack to acknowledge the alarm. If there are other loops withalarm conditions, the Alarm display switches to the next loop in alarm.Acknowledge all alarms to clear the global alarm digital output. (Youmust acknowledge each alarm before displays and keyboard operationwill resume.)

NOTE

In the 4 and 8 CLS, the controller cannot detect all RTD openand RTD short failures. Detection of open or shorted RTDsdepends on which wires are open or shorted.

Symbol Alarm Message Alarm Type

FS TC Break Thermocouple break

FS (RO) RTD Open RTD break

FS (RS) RTD Short RTD Short

HP No message High process alarm

HD No message High deviation alarm

LD No message Low deviation alarm

LP No message Low process alarm

LOOP PROCESS UNITS


02 180 ºFLP 180 AUTO 0

Engineering Units

Output Percentage

SetpointAlarm Symbols

Loop numberor Name

Process Variable


Using the CLS

Job Display

Job display appears only if:

• You have turned on the Remote Job Select function. (This function is explained in Setup.)

• You have selected a job from the job load menu.

When you load a job, Job display shows you the following screen:

If you remotely loaded the job, Job display looks like this:

If you modify a job's parameters while the job is running, you'll see thisjob message:

If an alarm occurs, the controller switches to Single Loop Display.

LOOP PROCESS UNITS


JOB 3 RUNNING

LOOP PROCESS UNITS


JOB 3 RUNNINGREMOTELY LOADED

LOOP PROCESS UNITS


JOB 3 RUNNING DATA MODIFIED


Using the CLS

Operator Menus

You can reach the following Operator Menus from Single Loop Display.(If your CLS is already installed, try each procedure as you read aboutit.)

Change Setpoint

To change the setpoint, go to Single Loop display of the loop you wishto change, and then press the Change Setpoint key. (The setpoint is thedesired temperature, pH, et cetera, for the process.) You should see adisplay like this:

• Press Yes to change the setpoint.

• Then press Yes or No to change the setpoint value.

• When you are satisfied with the setpoint value you have chosen, press Enter to save your changes and return to Single Loop Display; or

• To return to Single Loop display without saving your changes, press No or Back.

Manual/Automatic Control

Press the Man/Auto key to set a loop's control mode, set manual outputlevels, or automatically tune a loop. The control mode determineswhether the CLS automatically controls the process according to theconfiguration information you give it (Automatic control), or you set theoutput to a constant level (Manual control).

If both outputs are disabled when you press the Man/Auto key, you'llsee a display like this one:

LOOP PROCESS UNITS


03 SETPOINT ? 500 º F

LOOP PROCESS UNITS


MAN/AUTO CONTROLOUTPUTS DISABLED


Using the CLS

Press any key to exit this display. If at least one control output (heat orcool) is enabled, you'll see this display:

• Press Yes to change the mode.

• Press Yes or No to switch between Manual, Automatic, and Tune.

• To exit this menu and return to the Single Loop Display without sav-ing your changes, press Back.

• Press Enter to save your changes. If you have set the mode to Man-ual, you can now set the manual heat and cool output levels.

Manual Output Levels

The Manual Output Levels menu will only appear if you have set thecurrent loop to Manual control. This menu lets you set the manualoutput levels for the enabled outputs. The cool output menu is just likethe heat output menu, except that the word COOL replaces the wordHEAT in the display. You should see a display like the one below:

• Press Yes to change the output power.

• Then press Yes or No to select a new output power level.

• When you are satisfied with the power level you have chosen, press Enter to store your changes.

• To discard your changes and return to Single Loop display, press Back.

LOOP PROCESS UNITS


01 CONTROLSTATUS ? AUTO

LOOP PROCESS UNITS


01 SET HEATOUTPUT ? 90%


Using the CLS

Autotune

If you set the current loop's control status to TUNE and press Enter, thecontroller automatically sets the loop to Manual control, 100% output.(If you selected a continuous output limit, the controller sets the loop tothe output limit.) The autotune function then calculates the appropriatePID constants for the loop and puts the loop in automatic control withthe calculated PID values.

The Autotune function will abort if:

• Process variable goes over 75% of the setpoint. Remember, the con-troller is at 100% output or at the output limit you set.

• It has not calculated PID constants after 10 minutes (due to heater failure, sensor failure, et cetera.)

If the autotune function aborts, it puts the loop into its previous controlstate (Automatic control or Manual control at the previous outputpercentages.)

To automatically tune a loop, follow these steps:

1. Make sure the process is cold (or stable and well below setpoint).

2. Initiate Autotune:

a. Use the front panel keypad to go to Single Loop Display

b. Press the Man/Auto key

c. Choose Tune

d. Press Enter.

The Tune indicator will begin flashing and the controller will go back toSingle Loop Display. The Tune indicator will keep flashing as long asthe loop is tuning.

Ramp/Soak

If you have a CLS without the Ramp/Soak option, pressing the Ramp/Soak key has no effect. If you have a CLS with Ramp/Soak installed,please refer to the Ramp/Soak Appendix at the end of this manual.


Setup

The Setup menus let you change the CLS detailed configurationinformation.

If you have not set up a CLS before, or if you don't know what values toenter, please read first the Tuning and Control section, which containsPID tuning constants and useful starting values.

How to Enter the Setup Menus?

1. In Single Loop Display, select the loop you wish to edit.

2. While still in Single Loop Display, enter the pass sequence below: Press Enter, Alarm Ack, Change Setpoint.

3. The first setup menu appears.

NOTE

For your protection, CLS reverts to Single Loop Display Ifyou don't make any changes for three minutes.

How to edit a menu?

• Press Yes to select this menu or No to advance to the next menu.

• press Yes or No to toggle between the options in your menu.

• Press Enter to store the value you have selected.

• If you decide not to edit the menu, press Back to stop editing and return to the main menu.

Each display contains the default value for that specific menu, andbelow each display you will see the range of choices for that menu.

The following sections tell more about the submenus for each of the sixmain menus. If you have a CLS with the Ramp/Soak option, there willalso be a Ramp/Soak menu. (Please refer to the Ramp/Soakdocumentation included with your CLS for use instructions.)

The next page shows the setup menus accessible from Single LoopDisplay.


Setup

Setup GlobalParameters?

Setup Loop Inputs?

Setup LoopControl Params?

Setup LoopOutputs?

Setup LoopAlarms?

Manual I/OTest?

Load setupfrom job?

Save setupto job?

Job select dig inputs?

Job sel dig insactive?

Output overridedig input?

Override digin active?

Startup alarmdelay?

Keyboard lockstatus?

Controlleraddress?

CommunicationsERR check?

Communicationprotocol?

Input type?

Pulse sampletime?

Input units?

Heat control PB?

Heat control TI?

Heat control TD?

Heat control filter?

Cool control PB?

Cool control TI?

Cool control TD?

Cool control filter?

Heat/Cool spread?

Heat control output?

Heat output type?

Heat outputcycle time? (TP)

SDAC menus(SDAC only)

Heat output action?

Heat output limit?

Heat outputlimit time?

Heat overrideoutput?

Heat output?

Cool controloutput?

Cool output type?

Cool output cycletime? (TP)

SDAC menus(SDAC only)

Cool outputaction?

Cool output limit?

Cool outputlimit time?

Cool overrideoutput?

Cool output?

Hi proc alarmsetpt?

Hi proc alarmtype?

Hi proc alarmoutput?

Dev alarm value?

Hi dev alarmtype?

Hi dev alarmoutput?

Lo dev alarmtype?

Lo dev alarm output?

Lo proc alarmsetpt?

Lo proc alarmtype?

Lo proc alarmoutput?

Alarm dead-band?

Alarm delay?

Digital inputs

Test digitaloutput?

Keypad test

Input scalingLo RDG? (Linear& Pulse)

Input scalingLo PV? (Linear &Pulse)

Input scalingHi RDG? (Linear& Pulse)

Input scalingHi PV? (Linear &Pulse)

Disp format?(Linear)

Input readingoffset ? (T/C)

Loop name?

EPROMinformation

Dig out polarityon alarm?

AC line freq?

Communicationsbaud rate?

Power upoutput status?

* Ramp/Soaktime base? (onlyif R/S installed

* If Ramp/Soak is installedin your controller, see Ramp/Soak Appendix atthe end of this Guide.

Input Filter?


Setup

Set up Global Parameters Menu

The Set up Global Parameters menu looks like this:

Below is the setup global parameters menu tree. Notice the defaultvalues inside the boxes.:

LOOP PROCESS UNITS


SETUP GLOBALPARAMETERS ?

Setup Global Parameters?

Load setup from job? 1

Save setup to job? 1

Job select dig inputs?NONE

Job sel dig ins active?LOW

Output override diginput? NONE

Override dig in active?LOW

Startup alarm delay?0 MINS

Keyboard lock status?OFF

Power up output status?OFF

Controller address? 1

Communications baud rate? 9600

Communicationsprotocol? ANA

Communications errcheck? BCC

AC line freq.?60 HERTZ

Dig out polarity on alarm?LOW

EPROM information


Setup

Load a Job

Use this menu to load any one of 8 saved jobs from the controller's frontpanel.

The following parameters are loaded as part of a job:

• PID constants, filter settings, setpoints and spread values

• Loop control status (Automatic or Manual) and output values (if the loop is in Manual control).

• Alarm functions (Off, Alarm, Control), setpoints, high\low process setpoints, high\low deviation setpoints and deadband settings, and loop alarm delay.

WARNING

All current job settings will be overwritten if you select ajob from memory. Save your current programming to ajob number if you want to keep it.

If you have enabled the remote job control function, this menu will bedisabled; you will not be able to load a job from the front panel. If youtry it, you'll see the message below.

Save Setup to Job

Use this menu to save the job information for every loop to one of 8 jobsin the CLS' battery-backed RAM.

If you have enabled the remote job control function, you will not be ableto save a job. If you try it, you'll see this message:

LOOP PROCESS UNITS


LOAD SETUPFROM JOB ? 1

LOOP PROCESS UNITS


CANNOT LOAD JOBREMOTE SELECT

LOOP PROCESS UNITS


SAVE SETUP TO JOB ? 1

LOOP PROCESS UNITS


CANNOT SAVE JOBREMOTE SELECT


Setup

Job Select Inputs

Use this menu to set the number of job select inputs. The controller usesthese inputs as a binary code that specifies the job number to run. Thenumber of inputs you choose in this menu controls the number of jobsyou can select remotely.

Below is the truth table that tells you which input states select whichjobs.

Selectable values: 1, 2, or 3 inputs, or None. These choices have thefollowing effect:

Job Select Input Polarity

Use this menu to set the polarity of the digital outputs used for jobselection.

Selectable values: High or Low.

When nothing is connected, the inputs are all False and Job 1 is selected(as shown in the truth table above).

Digital Input 3 Digital Input 2 Digital Input 1 Job #

F F F 1

F F T 2

F T F 3

F T T 4

T F F 5

T F T 6

T T F 7

T T T 8

Setting Enables

1 input Jobs 1-2

2 inputs Jobs 1-4

3 inputs Jobs 1-8

None (no inputs) Remote Select disabled

LOOP PROCESS UNITS


JOB SELECTDIG INPUTS ? NONE

LOOP PROCESS UNITS


JOB SEL DIG INSACTIVE ? LOW


Setup

Output Override Digital Input

Use this menu to set a digital input that sets all loops in manual output atoutput levels you select in the Outputs menu. This menu, and the nextone, let you configure a “panic button” or “kill switch” that sets alloutputs to the output override percentage you set in the Set up LoopOutputs main menu.

Selectable values: NONE or input number 1-8.

WARNING

Watlow Anafaze recommends that you install additionalexternal safety devices or over-temperature devices foremergency shutdowns. Do not rely solely on the outputoverride feature to shut down your process.

Output Override Input Polarity

Use this menu to toggle the polarity of the Output Override digital input.You can set the input to be active when Low or active when High.


Start-up Alarm Delay

Use this menu to set a start-up delay for process and deviation alarmsfor all loops. The controller does not report these alarm conditions forthe specified number of minutes after the controller powers up. (Thecontroller will always report failed sensor alarms, no matter what start-up delay you set.)

Selectable values: 0-60 minutes.

LOOP PROCESS UNITS


OUTPUT OVERRIDEDIG INPUT ? NONE

LOOP PROCESS UNITS


OVERRIDE DIG INACTIVE ? LOW

LOOP PROCESS UNITS


STARTUP ALARMDELAY ? 0 mins


Setup

Keyboard Lock Status

Use this menu to lock the front panel operator function keys ChangeSP, Man/Auto, and Ramp/Soak so that pressing these keys has noeffect. If you want to use these functions, turn off the Keyboard Lock.

Selectable values: On or Off.

Power-Up Output Status

Use this menu to set the initial power-up state of the control outputs toOff or Memory. If you choose Off, all control outputs are initially set toManual mode at 0% output level. If you choose Memory, the outputs arerestored to the last output state stored in memory.

WARNING

Do not set the CLS to start from memory if a memory-based restart is unsafe for your process.

Selectable values: Off or Memory.

Controller Address

Use this menu to set the CLS address. The controller address is used formultiple controller communications on a single 485 cable, so each CLSmust have a different address. Begin with address 1 for the firstcontroller and assign each subsequent controller the next higher address.

Selectable values: 1-32.

LOOP PROCESS UNITS


KEYBOARD LOCKSTATUS ? OFF

LOOP PROCESS UNITS


POWER UP OUTPUTSTATUS ? OFF

LOOP PROCESS UNITS


CONTROLLERADDRESS ? 1


Setup

Communications Baud Rate

Use this menu to set the Communications Baud Rate.

Selectable values: 2400 or 9600.

Communications Protocol

Use this menu to set the communications protocol type.

Selectable values: ANA (Watlow Anafaze’s protocol), AB (AllenBradley’s), MOD (Modbus).

Communications Error Checking

This menu appears only when you choose ANA or AB as yourcommunications protocol. Use it to set the data check algorithm used inthe CLS communications protocol to Block Check Character (BCC) orto Cyclic Redundancy Check (CRC).

Selectable values: BCC or CRC.

CRC is a more secure error checking algorithm than BCC, but itrequires more calculation time and slows the CLS communications.BCC ensures a high degree of communications integrity, so WatlowAnafaze recommends that you use BCC unless your applicationspecifically requires CRC

NOTEIf you are using ANASOFT, be sure to configure ANAIN-STL for the same Error Checking method and the sameBaud Rate that you set in this menu and in the next one.

LOOP PROCESS UNITS


COMMUNICATIONSBAUD RATE ? 9600

LOOP PROCESS UNITS


COMMUNICATIONS

PROTOCOL?ANA

LOOP PROCESS UNITS


COMMUNICATIONSERR CHECK ? BCC


Setup

AC Line Frequency

Use this menu to configure the controller to match an AC line frequencyof 50 or 60 Hz. (This function is provided for international users whorequire 50 Hz lines.) Since the controller reduces the effect of powerline noise on the analog measurement by integrating the signal over theperiod of the AC line frequency, the controller's noise rejection willsuffer if the line frequency is not set correctly.

Selectable values: 50 Hz or 60 Hz.

NOTEYou must switch power to the CLS on and off for a changein AC line frequency to take effect.

Digital Output Polarity

Use this menu to set the polarity of the digital outputs used for alarms.


EPROM Information

This is a view-only display. It shows the controller's EPROM versionand checksum.

Press any key to return to the Set up Global Parameters menu.

LOOP PROCESS UNITS


AC LINE FREQ ?60 HERTZ

LOOP PROCESS UNITS


DIG OUT POLARITYON ALARM ? LOW

LOOP PROCESS UNITS


CLS164V03.02 CS=2233


Setup

Set up Loop Input

The Set up Loop Input main menu lets you access menus which changeparameters related to the loop input:

• Input type

• Input units

• Input scaling and calibration

• Input filtering

The next section explains how to use the Input menus to configure yourcontroller.

Below is the setup inputs menu tree. Notice the default values inside theboxes.

LOOP PROCESS UNITS


SETUP LOOP 02INPUT ?

Setup Loop Inputs?

Input Type? J T/C

Pulse Sample Time? 1s(only for pulse input)

Loop Name?

Input Units? ºF

Input Reading Offset?ºF (only for T/C inputs)

Disp Format?-999 to 3000 (only for linear)

Input Scaling Hi PV?1000 (linear & pulse)

Input Scaling Hi RDG?100.0%FS (linear&pulse)

Input Scaling Lo PV? 0(linear & pulse)

Input Scaling Lo RDG?.0%FS (linear & pulse)

Input Filter?3 Scans


Setup

Input Type

Use this menu to configure the input sensor for each loop as one of theseinput types:

• Thermocouple types (J, K, T, S, R, B and E).

• RTD (4 and 8CLS). Two ranges: RTD1 (Platinum Class A) and RTD2 (Platinum Class B).

• Linear inputs.

• Skip (an input type available for unused channels.) The scanning dis-play doesn't show loops you've set to Skip.

The following tables show the input types and ranges.

Input Type Range in ºF Range in ºC* Accuracy:

25ºCAmbient

* Accuracy:0-50ºC Full

Temp. Range

ºC ºC ºF ºC ºF

J T/C -350 to 1400 -212 to 760 ±0.5 ±0.9 ±1.1 ±2.0

K T/C -450 to 2500 -268 to 1371 ±0.6 ±1.2 ±1.35 ±2.7

T T/C -450 to 750 -268 to 399 ±1.3 ±2.4 ±2.9 ±5.4

S T/C 0 to 3200 -18 to 1760 ±2.5 ±4.5 ±5.6 ±10.1

R T/C 0 to 3210 -18 to 1766 ±2.5 ±4.5 ±5.6 ±10.1

B T/C 150 to 3200 66 to 1760 ±6.6 ±12.0 ±14.9 ±27.0

E T/C -328 to 1448 -200 to 787

Pulse 0-2 KHz

Skip Loop is not scanned or displayed

Linear See the Linear Scaling section

* True for 10% to 100% of span.

LOOP PROCESS UNITS


01 INPUT TYPE ? J T/C


Setup

RTD Ranges (4 and 8CLS)

Pulse Sample Time

You can connect a digital pulse signal of up to 2 KHz to the controller'spulse input. In this menu, you specify the pulse sample period. (This isthe second menu of the Set up Loop Inputs menu for the pulse inputloop only.) Every sample period, the number of pulses the controllerreceives is divided by the sample time. The controller scales thisnumber and uses it as the pulse loop's process variable.

Selectable Range: 1-20 seconds.

Loop Name

Use this menu to name your loop using two-characters. After specifyinga new name, it is placed on the single loop display instead of the loop’snumber.

Input Units

Use this menu to choose a three-character description of the loop’sengineering units

Name Range in ºF Range in ºC ResolutionProbe

Temp. In ºC

Accuracy: 25ºC AmbientºC ºF

Accuracy: 0-50ºC Ambient

ºC ºF

RTD1 -148.0 to 527.0

-100.0 to 275.0

0.023 ºC 25 ±0.35 ±0.63 ±0.5 ±0.9

275 ±1 ±1.8 ±1.5 ±2.7

RTD2 -184 to 1544

-120 to 840 0.062 ºC 25 ±0.9 ±1.62 ±2.8 ±5.04

840 ±1.1 ±1.98 ±4.3 ±7.74

LOOP PROCESS UNITS


05 INPUT PULSESAMPLE TIME ? 1s

LOOP PROCESS UNITS


A5 LOOPNAME ? A5

LOOP PROCESS UNITS


02 INPUT UNITS ? ºF


Setup

Selectable values: The table below shows the character set for inputunits.

Input Reading Offset

This menu does not appear if the input type is linear, pulse, or skip.Use it to make up for the input signal's inaccuracy at any given point.For example, at temperatures below 400 ºF, a type J thermocouple maybe inaccurate (“offset”) by several degrees F. Use an independentthermocouple or your own calibration equipment to find the offset foryour equipment. To correct for offset errors, change the factory defaultsetting to a positive or negative value for the loop you are editing. (Apositive value increases the reading and a negative value decreases it.)

Selectable range: For thermocouples, infrared inputs and RTD2s, theoffset correction ranges from -300 to +300.

For RTD1s and IR inputs set to Average mode, the offset range is 300.0to +300.0.

Linear Scaling Menus

The linear scaling menus appear under the Set up Loop Inputs mainmenu. Linear scaling is available for linear and pulse inputs only. It letsyou scale the “raw” input readings (readings in millivolts or Hertz) tothe engineering units of the process variable.

NOTE

Linear scaling menus appear only if the loop's input type isset to Linear (or, for some menus, to Pulse).

For linear inputs, the input reading is in percent (0 to 100%)representing the 0-60 mV input range of the CLS. For pulse inputs, theinput reading is in Hertz (cycles per second.)

Input Character Sets for Units

Thermocouple, and RTD ºF or ºC

Linear & Pulse 0 to 9, A to Z,%, /, degrees, space

LOOP PROCESS UNITS


02 INPUT READINGOFFSET ? 0 ºF


Setup

The scaling function is defined by two points on a conversion line. Itrelates the high PV to the high reading and the low PV to the lowreading to define the line. The engineering units of the process variablecan be any arbitrary units. The graph below shows PSI as an example.

Before you enter the values that determine the two points for theconversion line, you must choose an appropriate display format. TheCLS has six characters available for process variable display; select thesetting with the desired number of decimal places before and after thedecimal point. Use a display format that matches the range andresolution of the process variable. The display format you choose isused for the setpoint, alarms, deadband, spread, and proportional band.

The PV (Process Variable) range for the scaled input is between the PVvalues that correspond to the 0% and 100% input readings. For the pulseinput, it is between the 0 Hz and 2000 Hz readings. This PV rangedefines the limits for the setpoint and alarms, as shown here.

NOTEFor example linear scaling calculations, see Linear Scalingsection.

ProcessVariable

InputReading

0 PSI0%0 m V0 Hz

100%60 m V2000 Hz

HiPV

Lo PV

LoRDG

HiRDG

}Linearin}Pulse in

Range


Setup

Display Format

This menu appears under the Set up Loop Inputs main menu. It lets youselect a display format for a linear input. Choose a format appropriatefor your input range and accuracy. (You will only see the DisplayFormat menu if you are editing a linear input.)

Selectable values: The CLS has several available display formats, asshown below. This table also shows the high and low PV values.

High Process Value

This menu appears under the Set up Loop Inputs main menu. Use it toenter a high process value. The high process value and the high readingvalue together define one of the points on the linear scaling function'sconversion line.

Selectable values: See table on the previous page.

Display Format Default High PV Default Low PV

-9999 to +30000 10000 0

-999 to +3000 1000 0

-999.9 to +3000.0 1000.0 .0

-99.99 to +300.00 100.00 .00

-9.999 to +30.000 10.000 .000

-.9999 to +3.0000 1.0000 .0000

LOOP PROCESS UNITS


04 DISP FORMAT ?-999 to 3000

LOOP PROCESS UNITS


01 INPUT SCALINGHI PV ? 1000 ºF


Setup

High Reading

Use this menu to enter the input level that corresponds to the highprocess value you entered in the previous menu. For linear inputs, thehigh reading is a percentage of the full scale input range. For pulseinputs, the high reading is expressed in Hz.

The 100% full scale input value is 60 mV for the linear input type.

Selectable range: Any value between -99.9 and 999.9. However, youcannot set the high reading to a value less than or equal to the lowreading.

Low Process Value

Use this menu to set a low process value for input scaling purposes. Thelow process value and the low reading value together define one of thepoints on the linear scaling function's conversion line.

Selectable values: See table under Display Format.

Low Reading

Use this menu to enter the input level that corresponds to the lowprocess value you selected in the previous menu. For linear inputs, thelow reading is a percentage of the full scale input range; for pulseinputs, the low reading is expressed in Hz.

The full scale input value for the linear input type is 60 mV. For pulseinputs, it is 2000 Hz.

Selectable range: 99.9-999.9. You cannot set the low reading to a valuegreater than or equal to the high reading.

LOOP PROCESS UNITS


04 INPUT SCALINGHI RDG ? 100.0%FS

LOOP PROCESS UNITS


01 INPUT SCALINGLO PV ? 0 ºF

LOOP PROCESS UNITS


01 INPUT SCALINGLO RDG ? 0.0%FS


Setup

Input Filter

The CLS has two different types of input filter:

• A noise rejection filter that rejects high frequency input signal noise. This filter keeps a “trend log” of input readings. If a reading is out-side the filter's “acceptance band”, and later readings are within the acceptance band, the CLS ignores the anomalous reading. (The acceptance band for thermocouples is 5 degrees above and 5 degrees below the input reading. For linear inputs, it's 0.5% above and 0.5% below the input reading.) If later readings are also outside the accep-tance band, the CLS accepts the anomalous reading and calculates a new acceptance band. (You cannot adjust this input filter.)

• A standard resistor-capacitor (RC) filter that lets you dampen the input response if inputs change unrealistically or change faster than the system can respond. If the input filter is enabled, the process variable responds to a step change by going to 2/3 of the actual value within the number of scans you set.

If all input loops are enabled (none of them are set to SKIP) the CLSscans each input loop 6 times per second. The input filter applies to allinput types except those set to SKIP.

Selectable range: 0-255 scans. 0 disables the filter.

LOOP PROCESS UNITS


01 INPUT FILTER ? 3 SCANS


Setup

Set up Loop Control Parameters

Use these menus to change control parameters for heat and cool outputsof the selected loop, including:

• Proportional Band (PB or Gain), Integral (TI or Reset), and Deriva-tive (TD or Rate) settings.

• Output Filter.

• Spread between heat and cool outputs.

Below is the setup control parameters menu tree.

NOTEBoth heat and cool outputs have the same menus, so onlyone of each menu is shown here. The controller will showboth heat and cool menus even if the heat or cool output isdisabled. (See Set up Loop Outputs for help enabling ordisabling the heat or cool output.)Refer to Tuning and Control for help in selecting controlparameter values.

LOOP PROCESS UNITS


SETUP LOOP 01CONTROL PARAMS ?

Setup Loop ControlParams?

Heat/Cool Control PB?

Heat/cool Control TI?

Heat/Cool Control TD?

Heat/Cool Control Filter?

Heat/Cool Spread?


Setup

Heat or Cool Control PB

This menu allows you to set the Proportional Band (also known asGain).

NOTEThe CLS internally represents the proportional band (PB)as a gain value. When you edit the PB, you'll see the valueschange in predefined steps--small steps for narrow PB val-ues and large steps for wide PB values.

The controller calculates the default PB for each input type according tothe following equation:

Heat or Cool Control TI

This menu lets you set the Integral term, or Reset.

Selectable range: 0 (off) - 6000 seconds.

Heat or Cool Control TD

This menu lets you set the derivative constant.

Selectable range: 0-255 seconds.

LOOP PROCESS UNITS


02 HEAT CONTROL PB? 50 ºF

Default PB = (High Range - Low Range)

Gain

LOOP PROCESS UNITS


02 HEAT CONTROL TI ? 180 Sec/R

LOOP PROCESS UNITS


03 HEAT CONTROL TD ? 0 sec


Setup

Heat or Cool Output Filter

Use this menu to dampen the heat or cool output's response. The outputresponds to a step change by going to approximately 2/3 of its finalvalue within the number of scans you set here.

Selectable range: 0-255. Setting the output filter to 0 turns it off.

Heat and Cool Spread

Use this menu to set the spread between the heat and cool output and thespread of the On/Off control action.

Selectable ranges: 0 - 255, 25.5, 2.55, .255 or .0255, depending on theway you set up the Input menus.

LOOP PROCESS UNITS


04 HEAT CONTROLFILTER ? 2 SCANS

LOOP PROCESS UNITS


01 SPREAD ? 5 ºF


Setup

Set up Loop Outputs

Press Yes at this prompt to access menus to change loop outputparameters for the current loop, including:

• Enable or disable outputs

• Output type

• Cycle time (for TP outputs)

• SDAC parameters (for SDAC outputs)

• Control action

• Output level limit and limit time

• Output override

• Nonlinear output curve

.

Below is the setup outputs menu tree. Both heat and cool outputs havethe same menus, so only one of each menu is shown here.

LOOP PROCESS UNITS


SETUP LOOP 03OUTPUTS ?

Setup Loop Outputs?

Heat/Cool ControlOutput?

Heat/Cool Output Type?

Heat/Cool Output CycleTime? (TP only )

SDAC Menus(SDAC only )

Heat/Cool OutputAction?

Heat/Cool Output Limit?

Heat/Cool OutputLimit Time?

Heat/Cool OverrideOutput?

Heat/Cool Output?

SDAC Mode?

SDAC High Value?

SDAC Low Value?


Setup

Enable/Disable Heat or Cool Outputs

From this menu you can enable or disable the heat or cool output for thecurrent loop. If you want the loop to have PID control, you must enableone output. You can also disable a heat or cool control output and usethe output pin for something else, like an alarm.

Selectable values: Enabled or Disabled.

Heat or Cool Output Type

This menu lets you set the output type.

This table shows the available output types.

For an expanded description of these output types, see Tuning andControl.

Display Code

OutputType

Definition

TP Time proportioning

Percent output converted to a per-cent duty cycle over the pro-grammed cycle time.

DZC DistributedZero Crossing

Output on/off state calculated for every AC line cycle.

SDAC Serial DAC Output type for optional Serial Digital to Analog Converter.

ON/OFF On / Off Output either full ON or full OFF.

LOOP PROCESS UNITS


01 HEAT CONTROLOUTPUT ? ENABLED

LOOP PROCESS UNITS


03 HEAT OUTPUT TYPE ? TP


Setup

Heat or Cool Cycle Time

From this menu you can set the Cycle Time for Time Proportioningoutputs.

NOTEThe Cycle Time menu will only be present if the outputtype for the current loop is Time Proportioning.


SDAC Menus

If you attach the optional SDAC to an output, you must configure thatoutput for the SDAC using the following series of menus. The CLS willalso assign digital output #34 as a clock line for the SDAC. You won'tbe able to assign another function to output #34 while any loop's outputis set to SDAC.

SDAC Mode

From this menu you can toggle the SDAC between current and voltageoutput. The SDAC menus only appear if the output type for the loop isset to SDAC.

Selectable values: Current or voltage.

LOOP PROCESS UNITS


02 HEAT OUTPUTCYCLE TIME ? 10 s

LOOP PROCESS UNITS


01 SDAC MODE ? VOLTAGE


Setup

SDAC High Value

Use this menu to set a high value for the SDAC output. Set the high andlow value to match the range of the output device. For instance, if theoutput device has a 4-20 mA range, set the SDAC high value to 20.00mA and the SDAC low value to 4.00 mA. The controller converts 0%output to a 4.00 mA signal and 100% output to a 20.00 mA signal.

Selectable values: If the output is set to Voltage, the default high valueis 10.00 volts. If the output is set to Current, the default high value is20.00 mA. You cannot set the high value to be less than or equal to thelow value.

SDAC Low Value

Use this menu to set a low value for the SDAC output. Set the high andlow value to match the range of the output device. For instance, if theoutput device has a 0.00-10.00 V range, set the SDAC high value to10.00 V and the SDAC low value to 0.00 V. The controller converts 0%output to a 0.00 V signal and 100% output to a 10.00 V signal.

Selectable values: If the output is set to Voltage, the default low valueis 0.00 volts. If the output is set to Current, the default low value is 4.00mA. You cannot set the low value to be greater than or equal to the highvalue.

Heat or Cool Output Action

Use this menu to select the control action for the current output.Normally, heat outputs are set to reverse action and cool outputs are setto direct action.

Selectable values: Reverse or direct. For heat outputs, set to reverse; forcool outputs, set to direct.

LOOP PROCESS UNITS


03 SDAC HI VALUE ? 10.00 VDC

LOOP PROCESS UNITS


04 SDAC LO VALUE ? 0.00 VDC

LOOP PROCESS UNITS


01 HEAT OUTPUTACTION ? REVERSE


Setup

Heat or Cool Output Limit

Use this menu to limit the maximum PID control output for a loop's heatand cool outputs. This limit may be continuous, or it may be in effect fora specified number of seconds (see Output Limit Time below). If youchoose a timed limit, the output limit restarts when the controllerpowers up and when the output goes from Manual to Automatic control(via the front panel, when the controller changes jobs, or fromANASOFT). The output limit only affects loops under automaticcontrol. It does not affect loops under manual control.

Selectable range: 0-100%.

Heat or Cool Output Limit Time

Use this menu to set a time limit for the output limit.

Selectable values: 1-999 seconds (1 second to over 16 minutes), or toCONT (continuous).

Heat or Cool Output Override

Use this menu to set an output override percentage. (You can configurea digital input for the output override in the Set up Global Parametersmain menu.) If the current loop is in Automatic mode and a sensorfailure occurs, the loop switches to the output override percentage. Ifyou change the polarity of the override output to the active state--forinstance, by flipping a “kill switch” you have set up--every loopswitches to the output override percentage you set here.

Selectable range: 0-100%.

LOOP PROCESS UNITS


01 HEAT OUTPUT LIMIT ? 100%

LOOP PROCESS UNITS


03 HEAT OUTPUT LIMIT TIME ? CONT

LOOP PROCESS UNITS


03 HEAT OVERRIDE OUTPUT ? 0%


Setup

Heat or Cool Nonlinear Output Curve

Use this menu to select one of two nonlinear output curves for nonlinearprocesses.

Selectable values: Curve 1, Curve 2, or Linear.

These curves are shown in the figure below.

LOOP PROCESS UNITS


03 HEAT OUTPUT ? LINEAR

0 3 24

7

12

19

29

44

66

8

13

19

27

36

48

62

79

10

20

40

60

80

100

30

50

70

90

20

40

60

80

100

1

2

Linear

Outp

ut

Calculated by PID

20 40 60 80 100


Setup

Set up Loop Alarms

Press Yes at the Set up Loop Alarms prompt to access menus whichchange alarm function parameters for the current loop. The main alarmsmenu looks like this:

Below is the setup alarms menu tree.

Alarm Types

The CLS has three different kinds of alarms: failed sensor alarms,global alarms, and process alarms.

Failed Sensor Alarms

Failed sensor alarms alert you to T/C breaks and these RTD open orshort failures:

• Open + input.

• Open - input.

• Short between + and - input.

Failed sensor alarms alert you to T/C breaks. When the loop is inAutomatic or Tune mode and a failed sensor alarm occurs, the CLS setsthe loop to Manual control at the output override percentage you set inthe Set up Loop Outputs menus.

LOOP PROCESS UNITS


SETUP LOOP 04ALARMS ?

Setup Loop Alarms?

High Process AlarmSetpoint?

High Process AlarmType?

High Process AlarmOutput?

Deviation Alarm Value?

High Deviation AlarmType?

High Deviation AlarmOutput?

Low Deviation AlarmType?

Low Deviation AlarmOutput?

Low Process AlarmSetpoint?

Low Process AlarmType?

Low Process AlarmOutput?

Alarm Deadband?

Alarm Delay?


Setup

Global Alarms

Global alarms occur when a loop alarm set to Alarm (not Control) isunacknowledged, or when there are any unacknowledged failed sensoralarms. (If an alarm occurs, the CLS front panel displays an appropriatealarm code--see Using the CLS section.) Even if the alarm conditiongoes away, the global alarm stays on until you use the front panelAlarm Ack key (or ANASOFT) to acknowledge it.

Process Alarms

Process alarms include high and low deviation and high and low processalarms. You can set each of these alarms to Off, Alarm, or Control, asshown here.

• High process and high deviation alarms activate when the process variable goes above a value you set. They remain active until the process variable goes below that value minus the deadband. (See the next diagram)

• Any digital output not used as a control output can be assigned to one or more process variable alarms. The output is active if any of its alarms are active. All alarm outputs are active Low or active High, depending on the global alarm output polarity setting.

• Low process and low deviation alarms activate when the process variable goes below a value you set. They remain active until the process variable goes above that value plus the deadband. (The next diagram shows these alarms.)

Function Description

Off No alarm or control function

Alarm Standard alarm function

Control Digital output activities on alarm, deactivates when loop is not in alarm. Global alarm output does not activate.


Setup

When the controller powers up or the setpoint changes, deviation alarmsdo not activate until the process goes inside the deviation alarm band,preventing deviation alarms during a cold start. (High and low processalarms are always enabled.)

Use menus to set the following process alarm parameters for each loop:

• High and low process alarm type, setpoint, and digital output

• High and low deviation alarm type, deviation alarm value, and digi-tal output

• Alarm deadband

• Alarm delay

The setpoints, deviation alarm values, and deadband all use the samedecimal format as the loop's process variable.

Alarm Delay

You can set the CLS to delay normal alarm detection and alarmreporting. There are two kinds of alarm delay:

• Start-up alarm delay delays process alarms (but not failed sensor alarms) for all loops for a time period you set in the Set up Global Parameters main menu.

• Loop alarm delay delays failed sensor alarms and process alarms for one loop until the alarm condition is continuously present for longer than the loop alarm delay time you set.

NOTE

Failed sensor alarms are affected by the loop alarm delayeven during the start-up alarm delay time period.

High Alarm Limit

Setpoint

Low Alarm Limit

SP + Deviation

SP - Deviation

}Deadband

}Deadband

}Deadband

}Deadband

High deviation alarm on

High deviation alarm off

Low deviation alarm on

Low deviation alarm off

High process alarm off

High process alarm on

Low process alarm on

Low process alarm off


Setup

High Process Alarm Setpoint

Use this menu to select the setpoint (temperature or other value withinthe scaled sensor range) at which the high process alarm activates. Thehigh process alarm activates when the process variable (PV) goes abovethe high process setpoint. It deactivates when the PV goes below thehigh process setpoint minus the deadband value, if you have set adeadband value.

Selectable range: any point within the scaled sensor range.

High Process Alarm Type

Use this menu to turn off the high process alarm or set it to the alarm orcontrol function. (See the previous description for an explanation ofthese choices).

Selectable values: Off, Alarm, or Control.

High Process Alarm Output Number

Use this menu to choose the digital output that activates when the loopis in high process alarm. You can use this output to activate a secondalarm horn or buzzer. You can also use it to control your process. Forexample, you can set the output you have chosen to activate heating orcooling mechanisms, or to turn off the system.

NOTEAll digital outputs are OR'd together (combined). There-fore you can assign more than one alarm to the sameoutput number, and that output will be On if any of thosealarms is On.

Selectable values: any output number between 1 and 34, as long as it'snot already used for control or the SDAC clock, or you may selectNone.

LOOP PROCESS UNITS


04 HI PROC ALARMSETPT ? 1000 ºF

LOOP PROCESS UNITS


02 HI PROC ALARM TYPE ? OFF

LOOP PROCESS UNITS


01 HI PROC ALARMOUTPUT ? NONE


Setup

Deviation Band Value

Use this menu to set the deviation bandwidth, a positive and negativealarm or control point relative to the setpoint. If the setpoint changes,the alarm or control points also change. You can assign a separatedigital output to the high and low deviation alarm/control setpoints--sothat, for example, a high deviation alarm turns on a fan and a lowdeviation alarm turns on a heater.

Selectable values: 0-255, 25.5, 2.55, .255 or .0255, depending on theway you set up the Input menus.

High Deviation Alarm Type

Use this menu to disable the high deviation alarm function or set it to thealarm or control function. (The high deviation alarm activates if theprocess value (PV) rises above the deviation band value, and remainsactive until the PV goes below the deviation band value minus thedeadband value.)

Selectable values: Alarm, Control, Off

High Deviation Alarm Output Number

Use this menu to assign a digital output which activates when the loop isin high deviation alarm. The digital output only activates if you have setthe high deviation alarm type to Alarm or Control.


Selectable values: Any output number between 1 and 34, as long as thatoutput is not already used for control or the SDAC clock, or you mayselect None.

LOOP PROCESS UNITS


02 DEV ALARMVALUE ? 5 ºF

LOOP PROCESS UNITS


03 HI DEV ALARM TYPE ? OFF

LOOP PROCESS UNITS


01 HI DEV ALARMOUTPUT ? NONE


Setup

Low Deviation Alarm Type

Use this menu to turn Off the low deviation alarm or set it to Alarm orControl mode.

Selectable values: Off, Alarm, or Control.

Low Deviation Alarm Output Number

Use this menu to assign a digital output that activates when the loop isin low deviation alarm.


Selectable values: 1 and 34, as long as that output is not already usedfor control or the SDAC clock, or you may select None.

Low Process Alarm Setpoint

Use this menu to set a low process alarm setpoint. The low processalarm activates when the process variable goes below the low processalarm setpoint. It deactivates when the process variable goes above thelow process alarm setpoint plus the deadband.

Selectable range: Any value within the input sensor's range.

LOOP PROCESS UNITS


01 LO DEV ALARMTYPE ? OFF

LOOP PROCESS UNITS


04 LO DEV ALARMOUTPUT ? NONE

LOOP PROCESS UNITS


01 LO PROC ALARMSETPT ? 0 ºF


Setup

Low Process Alarm Type

This menu lets you turn off the low process alarm or set it to the Alarmor Control function.

Selectable values: Off, Alarm or Control.

Low Process Alarm Output Number

Use this menu to assign the digital output that activates when the loop isin low process alarm.


Selectable values: any from 1-34 that are not used for control or theSDAC clock.

Alarm Deadband

Use this menu to set an alarm deadband. This deadband value applies tothe high process, low process, high deviation, and low deviation alarmsfor the loop you are editing. Use the Alarm Deadband to avoid repeatedalarms as the PV cycles slightly around an alarm value.

Selectable values: 0 - 255, 25.5, 2.55, .255 or .0255, depending on theway you set up the Input menus.

LOOP PROCESS UNITS


02 LO PROC ALARM TYPE ? OFF

LOOP PROCESS UNITS


04 LO PROC ALARMOUTPUT ? NONE

LOOP PROCESS UNITS


03 ALARM DEADBAND ? 2 º C


Setup

Alarm Delay

Use this menu to set a loop alarm delay. There are two types of alarmdelay: the start-up alarm delay and loop alarm delay. Start-up alarmdelay (which you can set in the Set up Global Parameters main menu)delays process alarms (but not failed sensor alarms) for all loops for aspecified time after the controller powers up.

The loop alarm delay, in contrast, is set separately for each loop. Itdelays failed sensor and process alarms until the alarm condition hasbeen continuously present for longer than the alarm delay time. (Failedsensor alarms are not subject to the start-up alarm delay, but they areaffected by the loop's alarm delay during the start-up alarm delayperiod.)


LOOP PROCESS UNITS


04 ALARM DELAY ? 0 SECONDS


Setup

Manual I/O Test

Press Yes at this prompt to see menus which can help you test the digitalinputs, digital outputs and the controller’s keypad.

Below is the manual I/O menu tree.

Digital Input Testing

Use this menu to view the logic state of the 8 digital inputs as H (High--the input is at 5 volts or is not connected) or L (Low--the input is at zerovolts). The menu displays inputs 1 to 8 from left to right. Since inputsare pulled High when they are not connected, test an input by shorting itto controller common and making sure this menu shows the correct statefor that input.

Using This Menu

• Short the digital input you are testing to controller common. When you do that, the input's state should change to L.

• Press Yes or No to advance to the next menu.

• Press Back to return to the Manual I/O test main menu.

LOOP PROCESS UNITS


MANUAL I/OTEST ?

Manual I/O Test?

Digital Inputs?

Test Digital Output? 34

Digital Output Number34? Off

Keypad Test

LOOP PROCESS UNITS


DIGITAL INPUTS HHHHHHHH


Setup

Test Digital Output

Use this menu to select one of the digital alarm outputs to test in thenext menu.

Toggle Digital Output

Use this menu to manually toggle a digital output On or Off to test it.(You select the output to test in the previous menu.) On may be Low orHigh depending on the digital output polarity you set in the OutputPolarity menu. (All outputs are set to Off when you exit Manual I/OTest menu.)

Selectable values: On or Off.

Keypad Test

Use this menu to test the keypad.

• Press any key to test the keypad. The CLS will display the name of the key you have pressed.

• Press No twice to advance to the next menu.

LOOP PROCESS UNITS


TEST DIGITAL OUTPUT ? 34

LOOP PROCESS UNITS


DIGITAL OUTPUTNUMBER 17? OFF

LOOP PROCESS UNITS


KEYPAD TESTQUIT = "NO" + "NO"


PID Tuning and Control

PID Tuning and ControlIntroduction

This chapter explains PID control and supplies some starting PID valuesand tuning instructions, so that you can use control parametersappropriate for your system. If you would like more information on PIDcontrol, consult the Watlow Anafaze Practical Guide to PID.

The control mode dictates how the controller responds to an inputsignal. The control mode is different from the type of control outputsignal (like analog or pulsed DC voltage). There are several controlmodes available: On/Off, Proportional (P), Proportional and Integral(PI), Proportional with Derivative, and Proportional with Integral andDerivative (PID). P, PI, or PID control are necessary when processvariable (PV) cycling is unacceptable or if the process or setpoint (SP) isvariable.

NOTEFor any of these control modes to function, the loop mustbe in automatic mode.



Control Modes

The next sections explain the different modes you can use to control aloop.

On/Off Control

On/Off control is the simplest way to control a process; a controllerusing On/Off control turns an output on or off when the process variablereaches a certain limit above or below the desired setpoint. You canadjust this limit, since Watlow Anafaze controllers use an adjustablespread. For example, if your setpoint is 1000 ºF, and your limit (spread)

is 20 ºF, the output switches On when the process variable goes below

980 ºF and Off when the process goes above 1000 ºF. (The nextdiagram shows a process under On/Off control.)

Proportional Control

A process using On/Off control frequently cycles around the setpoint.When process variable cycling is unacceptable or the process or setpointare variable, use proportional control. Proportional control, or Gain,eliminates cycling by increasing or decreasing the output proportional tothe process variable's distance from the setpoint.

The limits of proportional control are defined by the Proportional Band(PB); outside this band of control, the output is either 100% or 0%. Forexample--using the same values from the example above and a PB of20º---the output is:

• 50% when the process variable is 990 ºF

• 75% when the process variable is 985 ºF

• 100% when the process variable is 980 ºF or below.



However, a process which uses only Proportional control may settle at apoint above or below the setpoint; it may never reach the setpoint at all.This behavior is known as “offset” or “droop”. (This diagram shows aprocess under proportional control only.)

Proportional and Integral Control

For Proportional and Integral control, use the Integral term, or Reset,with Proportional control. The Integral term corrects for offset byrepeating the Proportional band's error correction until there is no error.For example, if a process tends to settle about 5 ºF below the setpoint,use Integral control to bring it to the desired setting. (The next diagramshows a process under proportional and integral control.)



Proportional, Integral and Derivative Control

For an improved level of control, use Derivative control withProportional or Proportional and Integral control. Derivative controlcorrects for overshoot by anticipating the behavior of the processvariable and adjusting the output appropriately. For example, if theprocess variable is rapidly approaching the setpoint, Derivative controlreduces the output, anticipating that the process variable will reachsetpoint. Use it to eliminate the process variable overshoot common toPI control. (This figure shows a process under full PID (Proportional,Integral, and Derivative) control).

Control Outputs

The CLS provides a 5 Vdc digital output signal for PID control outputs.These outputs normally control the process using relays. WatlowAnafaze can also provide a Serial Digital to Analog converter (SDAC)for 0-5 Vdc, 0-10 Vdc, or 4-20 mA analog output signals.

Digital Output Control Forms

The next section explains different modes for control outputs.

On/Off

On/Off output is very simple: it turns the output on or off according tothe control signal of the On/Off control.



Time Proportioning (TP)

Time Proportioning attempts to digitally simulate an analog outputpercentage by turning the output on or off for each time step so that thecumulative average of the output is the desired setting. You must enter acycle time for TP outputs. The cycle time is the time over which theoutput is proportioned, and it can be any value from 1 to 255 seconds.For example, if the output is 30% and the Cycle Time is 10 seconds,then the output will be on for 3 seconds and off for seven seconds. Thefigure below shows typical TP and DZC graphs.

Distributed Zero Crossing (DZC)

DZC output is essentially a Time Proportioning output. However, foreach AC line cycle the controller decides whether the power should beOn or Off. There is no Cycle Time since the decision is made for eachline cycle. Since the time period for 60 Hz power is 16.6 ms, theswitching interval is very short and the power is applied uniformly.Switching is done only at the zero crossing of the AC line, which helpsreduce electrical “noise”.

DZC output is primarily used for very fast acting electrical heating loadsusing Solid State Relays (SSRs). For instance, the open air heater coil isan example of a fast acting load. Do not use DZC output forelectromechanical relays.

The combination of DZC output and a solid state relay caninexpensively approach the effect of analog phase angle fired control.

Analog Outputs

The Serial DAC is an optional analog output module for the CLS. It letsthe controller output precision analog voltages or currents--typically forprecision open-loop control, motor or belt speed control, or phase anglefired control. To use it, set the output type for the appropriate loop toSDAC.

Output Digital Filter

The output filter digitally filters the PID control output signal. It has arange of 0-255 levels, which gives a time constant of 0-127.5 seconds.Use the output filter if you need to filter out erratic output swings due toextremely sensitive input signals, like a turbine flow signal or an openair thermocouple in a dry air gas oven.



The output filter can also enhance PID control. Some processes are verysensitive and require a high PB, so normal control methods areineffective. You can use a smaller PB- and get better control- if you usethe digital filter to reduce the high and low process output swings.

You can also use the filter to reduce output noise when a largederivative is necessary, or to make badly tuned PID loops and poorlydesigned processes behave properly.

Reverse and Direct Action

Reverse action is an output control action in which an increase in theprocess variable causes a decrease in the output. Direct action is anoutput control action in which an increase in the process variable causesan increase in the output. Heating applications normally use reverseaction and cooling applications usually use direct action.



Setting Up and Tuning PID Loops

After you have installed your control system, tune each control loop andthen set the loop to automatic control. (When you tune a loop, youchoose PID parameters that will best control the process.) If you don'tmind minor process fluctuations, you can tune the loop in automaticcontrol mode. This section gives PID values for a variety of heating andcooling applications.

If you don't know the PID values that are best for your process, try theCLS Autotune feature. The autotune feature is accessible from thecontroller's Man/Auto key. (For more information about Autotune, seeUsing the CLS.)

NOTETuning is a slow process. After you have adjusted a loop,allow about 20 minutes for the change to take effect.

Proportional Band (PB) Settings

The table below shows PB settings for various temperatures indegrees F.

As a general rule, set the PB to 10% of the setpoint below 1000º and 5%

of the setpoint above 1000º. This setting is useful as a starting value.

TemperatureSetpoint

PBTemperature

SetpointPB

TemperatureSetpoint

PB

-100 to 99 20 1100 to 1199 75 2200 to 2299 135

100 to 199 20 1200 to 1299 80 2300 to 2399 140

200 to 299 30 1300 to 1399 85 2400 to 2499 145

300 to 399 35 1400 to 1499 90 2500 to 2599 150

400 to 499 40 1500 to 1599 95 2600 to 2699 155

500 to 599 45 1600 to 1699 100 2700 to 2799 160

600 to 699 50 1700 to 1799 105 2800 to 2899 165

700 to 799 55 1800 to 1899 110 2900 to 2999 170

800 to 899 60 1900 to 1999 120 3000 to 3099 175

900 to 999 65 2000 to 2099 125 3100 to 3199 180

1000 to 1099 70 2100 to 2199 130 3200 to 3299 185



Integral Term (TI) Settings

This table shows TI settings vs. Reset settings.

As a general rule, use 60, 120, 180, or 240 as a starting value for the TI.

Derivative Term (TD) Settings

This table shows Derivative term (TD) versus Rate Minutes (RM);Rate=TD/60.

As a general rule, set the TD to 15% of TI as a starting value.

TI(secs./repeat)

Reset(repeats/min)

TI(secs./repeat0

Reset(repeats/min)

30 2.0 210 0.28

45 1.3 240 .25

60 1.0 270 .22

90 .66 300 .20

120 .50 400 .15

150 .40 500 .12

180 .33 600 .10

TD(secs./repeat)

Rate(repeats/min)

TD(secs./repeat)

Rate(repeats/min)

5 .08 35 .58

10 .16 40 .66

15 .25 45 .75

20 .33 50 .83

25 .41 55 .91

30 .50 60 1.0



General PID Constants by Application

This section gives PID values for many applications. They are useful ascontrol values or as starting points for PID tuning.

Proportional Band Only (P)

PB: Set the PB to 7% of the setpoint (SP) (Example: Setpoint = 450, soProportional Band = 31).

Proportional with Integral (PI)

PB: Set the PB to 10% of SP (Example: Setpoint = 450, so PB = 45).

Set TI to 60.Set TD to Off.Set the Output Filter to 2.

PI with Derivative (PID)

PB: Set the PB to 10% of the SP (Example: Setpoint = 450, so PB = 45).

Set the TI to 60.Set the TD to 15% of the TI (Example: TI = 60, so TD = 9).Set the Output Filter to 2.

The next table shows general PID constants by application.

Application PB TI TD FilterOutputType

CycleTime

Action

Electrical heat w/ SSR 50º 60 15 4 TP 3 Reverse

Electrical heat w/ EM relays

50º 60 15 6 TP 20 Reverse

Cool w/ solenoid valve 70º 500 90 4 TP 10 Direct

Cool w/ fans 10º off 10 4 TP 10 Direct

Electric heat w/ open heat coils

30º 20 off 4 DZC - Reverse

Gas heat w/ motorized valves

SP>1200

60º

100

120

240

25

40

8 DAC or

SDAC

- Reverse

Electric heat w/ phase angle controlled SCR

60º 60 15 4 DAC or SDAC

- Reverse

Extuders w/ cooling gas heat w/ SSR (set spread to 8)

50º 300 120 4 TP 3 Reverse


Troubleshooting

TroubleshootingThe next few sections describe general troubleshooting for the CLS.Later sections describe specific procedures, like checking an input,changing the EPROM, and testing the controller.

First, Check your Installation

Please bear in mind that, even in stand-alone systems, the controller isonly part of your control system. Often, what appears to be a problemwith the CLS is really a problem with other equipment- so check thesethings first:

• Controller is installed correctly. (See Installation for help.)

• Inputs — like thermocouples and RTDs — are installed correctly, and they're working.

Second, Replace Unit

If you are certain that the controller is installed correctly, you can tryreplacing the CLS with a spare CLS. If the spare unit works correctly,then the problem is specific to the CLS you replaced.

WARNING

If the controller wasn't installed correctly--for instance, ifyou have shorted sensor inputs to high voltage lines or atransformer is shorted out--and you replace the CLS with aspare unit, the spare unit will break, and you'll need tosend both units to Watlow Anafaze for repair. Therefore,make sure you have checked the installation before replac-ing the controller.

If you need to update the CLS Erasable Programmable Read-OnlyMemory (EPROM), please refer to the third section in this chapter,Changing the EPROM.

No Key Reset

If the instructions in this manual tell you to perform a “No Key Reset”,please do the following:

1. Power down the unit.

2. Press and hold the No key on the front panel. Power up the unit.


Troubleshooting

NOTEA No key reset clears the CLS memory and resets itsparameters to their default values. If you have a stand-alone system, there is no way to recover your originalparameters. If you have a computer-supervised systemwith ANASOFT, ANASOFT can store a copy of yourparameters to a job file.

WARNING

Do not attempt to repair the controller yourself. If the trou-bleshooting procedures in this chapter do not solve yoursystem's problems, call the Technical Services departmentfor additional troubleshooting help. If you need to returnthe unit to Watlow Anafaze for testing and repair, Techni-cal Services will issue you an RMA number- see Returningthe Unit below.

Returning your Unit

If you need to return the CLS, please contact Watlow by phone, fax or e-mail (see contact information on cover) for a ReturnedMaterials Authorization (RMA) number. The RMA number helps ustrack your equipment and return it to you as soon as possible.

Troubleshooting Stand-Alone Systems

The CLS is only part of a control system; be sure to check other parts ofthe system, like thermocouples, before you assume that the unit isbroken. To check inputs and outputs, follow these procedures.

Checking an Analog Input

To check any input except the pulse input, follow these steps:

1. Disconnect the sensor wiring.

2. Set the input sensor to type J T/C from the Setup menus.

3. Place a short across the input.

The process variable should indicate ambient temperature. If it does not,call Watlow Anafaze for an RMA number and return the unit for repair.

To check thermocouple inputs, remove the thermocouple leads and usean ohm meter to measure between the In+ and In- terminals of TB1.Thermocouple inputs should not read above 200 ohms.

To check RTD inputs, measure between the In+ and In- terminals ofTB1. RTD inputs should read between 20 and 250 ohms.


Troubleshooting

Checking Digital I/O

The following steps will help you test digital inputs and outputs.

TB-18 and TB-50 Test

1. Plug in the CLS power supply, if you have not already done so.

2. Measure the +5Vdc supply at your TB-18 or TB-50:

A. Connect the voltmeter's Common lead to your TB-18 screw terminal #2 or TB-50 screw terminal #3.

B. Connect the voltmeter's Power lead to your TB-18 or TB-50 screw terminal #1. The voltage should be 4.75 to 5.25 Vdc.

Control and Digital Output Testing

1. Connect a 500 ohm to 100 Kohm resistor between the +5V pin (TB-18 or TB-50 screw terminal #1) and the output pin you want to test.

2. Connect the Common lead to the output pin.

3. Connect the voltmeter positive lead to the +5V pin.

4. If you are testing a PID control output, use the Man/Auto front panel key to turn the output on (100%) and off (0%). When the out-put is off, the output voltage should be less than 1V. When the out-put is on, the output voltage should be between 3.75 and 5.5V.

5. If you are testing a digital output, use the Manual I/O Test menu to turn the output on and off. (See Setup for information on the Man-ual I/O Test menu.)

Digital Input Testing

1. Go to the digital input test menu (under the Manual I/O Test main menu). This menu shows whether the digital inputs are H (high, or open) or L (Low, or closed).

2. Attach a wire to the terminal of the digital input you want to test.

A. When the wire is connected only to the digital input terminal, the digital input test menu should show that the input is H (High, or open).

B. When you connect the wire to logic ground (TB-18 pin #2; TB-50 pin #3), the digital input test menu should show that the input is L (Low, or closed).


Troubleshooting

Checking Computer Supervised Systems

Four elements must work properly in a computer supervised system thatuses an IBM-compatible computer and ANASOFT:

• The CLS.

• The computer and its RS-232 or RS-485 serial interface.

• The RS-232 or RS-485 communications line.

• The computer's software.

For CLS troubleshooting, disconnect the communications line from thecomputer before you follow the troubleshooting steps explained in theprevious sections. Troubleshooting for the computer andcommunications are explained in the sections below.

Computer Problems

If you are having computer or serial interface problems, check thefollowing:

• Make sure you are using DOS 5.0 or a later version of DOS.

• Check the communications interface, cables, and connections. Make sure the serial interface is set according to the manufacturer's instructions.

• To test an RS-232 interface, buy an RS-232 troubleshooterfrom Radio Shack or an equivalent supplier. Attach the trou-bleshooter between the CLS and the computer. When ANA-SOFT sends data to the CLS, the troubleshooter's TX LEDshould blink. When ANASOFT receives data from the CLS,the RX LED should blink.

• You can also connect an oscilloscope to the transmit orreceive line to see whether data is being sent or received. Ifthe serial interface does not function, contact your computerservice representative.

NOTEMost communications problems are due to incorrect wiringor incorrectly set communications parameters. Therefore,check the wiring and communications settings first.

If you have more than one controller, or you are using more than 50 feetof communications wiring, you must use RS-485 communications.Otherwise, you can use RS-232 communications. The CLS isconfigured for RS-232 communications when it is shipped. If you areusing RS-485 communications, you must set the internal RS232/RS485selection jumpers to the correct position. (See Chapter 2: Installation forinformation about changing jumpers.)


Troubleshooting

From the setup menus, make sure that the communications parameters(address, error checking and baud rate) are set correctly for each CLS inyour system.

Every controller must have a separate address, starting with 1 andincreasing by 1 for each controller.

The error checking method and baud rate must be set the same way inthe controller's setup menus and in ANASOFT.

Ground Loops

On some computers, the RS-232 common wire is tied to earth ground.Since the CLS ground is also tied to earth ground, this arrangementcreates a ground loop which may affect communications and other CLSfunctions. To avoid ground loops, either use an optically isolatedcommunications adapter or disconnect the CLS from earth ground andtie a .1 µF capacitor from CLS DC common to earth ground.

Software Problems

ANASOFT

Consult the ANASOFT User’s Guide for help with ANASOFT.

User-Written Software

If you don't want to use ANASOFT as your software interface to theCLS, you are responsible for the correct operation of the software youbuy or write. You can request technical documentation from WatlowAnafaze if you want to write your own software. Watlow Anafaze willanswer any technical questions that arise during your softwaredevelopment process, but Watlow Anafaze does not otherwise supportuser software in any way.

Changing the EPROM

Changing the EPROM involves minor mechanical disassembly andreassembly of the controller, but you don't need any soldering orelectrical expertise. The only tools you need are a Phillips headscrewdriver and a small flathead screwdriver.

NOTEIf you change the EPROM, you must perform a No KeyReset for the EPROM change to take effect. A No KeyReset changes all controller parameters back to theirdefault values, so you must reenter the desired values fromANASOFT or from the controller front panel after youchange the EPROM.

1. Power down the controller. Be sure to take antistatic precautions.


Troubleshooting

2. Remove the two screws from the sides of the controller front panel.

3. Remove the electronics assembly from the case, as shown below.

4. Unscrew the four screws at the corners of the top board and care-fully unplug this board to access the bottom board (processor board), as shown below.

5. Find the installed EPROM. This is a 28 pin socketed chip which should have an Watlow Anafaze label on top of it. (If there is no label, a small window will be visible in the middle of the top of the chip.) Do not confuse the EPROM with the RAM; the RAM also has 28 pins, but it's in high profile socket, and it does not have a label or a window. (The component designation U2 is printed on the processor board next to the EPROM socket.) The next figure shows the EPROM and RAM chip.

EPROM

RAM


Troubleshooting

6. Remove the existing EPROM from its socket by prying it out with a small flathead screwdriver, as shown below.

7. The EPROM is shipped with its legs bent at an angle that best fits its packaging. Bend the legs slightly so that the legs line up with the holes in the EPROM socket. Don't try to bend the legs one at a time; instead, gently press the legs against a flat surface until they're at a 90-degree angle to the EPROM body, as shown below.

8. Carefully insert the new EPROM into the EPROM socket. Make sure that the chip is oriented so that its notch faces the same way as the part outline on the board.

9. Reverse steps 2 through 4 to reassemble the unit.

10. Do a No key reset to reinitialize the battery backed RAM. You must perform a No key reset for the unit to operate properly. (To do a No key reset, power down the controller. Then press the No key and power up the controller.)


Troubleshooting


Linear Scaling Examples

Linear Scaling ExamplesExample 1

Situation

A pressure sensor that generates a 4-20 milliamp signal is connected tothe CLS. The specifications of the sensor state that it generates 4milliamps at 0.0 PSI and 20 mA at 50.0 PSI.

Setup

The sensor is connected to a loop input set up with a resistor scalingnetwork to produce 60 millivolts at 20 mA. (See the Inputs section ofInstallation for more information on scaling networks.)

The sensor measures PSI in tenths, so the appropriate display format is -999.9 to +3000.0.

This table shows the input readings.

The scaling values are therefore:

PV Displayed

Sensor Input Reading (%FS)

50.0 PSI 20 100%

0.0 PSI 4 100%x(4ma/20 ma) = 20%

Parameter Low Value High Value

Process Value (PV) 0.0 PSI 50.0 PSI

Input Reading (RDG) 20.0 100.0


Linear Scaling

Example 2

Situation

A flow sensor connected to the CLS measures the flow in a pipe. Thesensor generates a 0-5V signal. The sensor's output depends on itsinstallation. Independent calibration measurements of the flow in thepipe indicate that the sensor generates 0.5 volts at three gallons perminute (GPM) and 4.75 volts at 65 GPM. The calibration instrumentsare precise to ñ1 gallon per minute.

Setup

The sensor is connected to a loop input set up with a resistor voltagedivider network to produce 60 millivolts at 5 volts. (See the Inputssection of the Installation chapter for information on scaling networks.)

The calibrating instrument is precise to ±1 gallon per minute, so theappropriate display format is -999 to +3000.

This table shows the input readings.

The scaling values are therefore:

PV Displayed

Sensor Input

Reading (%FS)

65 GPM 4.75 (4.75V / 5.00V) x 100%=95%

3 GPM 0.5 (0.5V / 5.00V) x 100%=10%


Process Value (PV) 3 GPM 65 GPM

Input Reading (RDG) 10.0 95.0


Linear Scaling Examples

Example 3

Situation

A pulse encoder which measures the movement of a conveyor isconnected to the CLS. The encoder generates 900 pulses for every inchthe conveyor moves. You want to measure conveyor speed in feet perminute (f/m).

Setup

The encoder input is connected to the CLS' pulse input. An one secondsample time gives adequate resolution of the conveyor's speed.

The resolution is:

So a display format of -99.99 to +300.00 is appropriate.

The input readings are as follows.

At the maximum pulse rate of the CLS (2000 Hz):

At zero hertz, the input reading will be 0.00 f/m.

Therefore, the scaling values are:


Process Value (PV) 0 f/m 11.11 f/m

Input Reading (RDG) 0 Hz 2000 Hz

1 pulse1 second

X60 seconds1 minute

X1 inch

900 pulsesX

1 foot

12 inches= 0.006 f/m

2000 pulses

1 secondX

60 seconds1 minute

X1 inch

900 pulsesX

1 foot

12 inches= 11.11 f/m


Linear Scaling


Appendix A: Ramp Soak

Appendix A: Ramp Soak Introduction

This Appendix will teach you how to set up and use Ramp/Soak profilesin CLS controllers.

The Ramp/Soak feature turns your controller into a powerful andflexible batch controller. Ramp/Soak lets you program the controller tochange a process setpoint in a preset pattern over time. This presetpattern, or temperature profile, consists of several segments. During asegment, the temperature goes from the previous segment’s setpoint tothe current segment’s setpoint.

• If the current segment’s setpoint is larger or smaller than the previ-ous segment’s setpoint, it is called a ramp segment.

• If the current segment’s setpoint is the same as the previous seg-ment’s setpoint, it is called a soak segment.

Each segment can have up to two triggers. At least one of these twotriggers must be true before the segment can start. While the input is nottrue, the profile waits (this wait state is called trigger wait).

You can use any one of the eight digital inputs for triggers. You can alsouse the same trigger for more than one segment or more than oneprofile.

Each segment can also have up to four events (external signalsconnected to the digital outputs). Events occur at the end of a segment.You can use any of the digital outputs that are not used for control or forthe SDAC clock for events.

R/S Features

• User-configurable time base: Watlow Anafaze’s Ramp/Soak lets you set your profiles to run for hours and minutes or for minutes and seconds—Whichever is appropriate for your installation.

• Repeatable profiles: You can set any profile to repeat from 1 to 99 times or continuously.

• Fast setup for similar profiles: You can set up one profile, then copy it and alter it to set up the rest.

• External reset: Use the CLS external reset menu to configure a dig-ital input you can use to reset a profile to the Ready state.



Specifications

Configuring Ramp/Soak

This section will teach you how to set up R/S profiles. The followingdiagram shows the R/S configuration menu tree.

Number of possible profiles 17

Number of times to repeat a profile 1-99 or con-tinuous

Number of segments per profile 1-20

Number of triggers per segment Up to 2

Type of triggers Latched/Unlatched

Number of possible inputs for triggers 8

Number of events per segment 4

Number of possible outputs for events(At least one of these outputs must be used for control)

34

Setup R/S profiles?

Edit R/S profile?

Copy Setup from profile?

Tolerance alarmTime?

Ready segmentsetpoint?

Ready segmentedit events?

External resetinput number?

Edit segmentnumber?

Segment time?

Segment setpoint?

Edit segment events?

Edit segmenttriggers?

Edit segment tolerance?

Last segment?

Repeat cycles?

Ready eventoutput XX

Segment eventoutput #?

Segment event active state?

Back

Back

Trigger input #? Trigger activestate?

Trigger latch status?No



Setting the R/S Time Base

The R/S time base menu is in the Setup Globals main menu.

Use this menu to set the time base in all your R/S profiles.

Selectable Values: Hours/Mins or Mins/Secs.

Editing R/S Parameters

You can reach the rest of the menus in this section from the SetupRamp/Soak profile main menu. This menu is located between the SetupLoop Alarms main menu and the Manual I/O Test main menu.

Answering Yes to this prompt allows you to setup or edit R/S profiles.

Choosing a Profile to Edit

Use this menu to choose a profile to set up or edit.

Selectable Values: A to Q (17 profiles).

LOOP PROCESS UNITS


RAMP/SOAK TIMEBASE? HOURS/MINS

LOOP PROCESS UNITS


SETUP RAMP/SOAKPROFILE?

LOOP PROCESS UNITS


EDIT RAMP & SOAKPROFILE? A



Copying the Setup from Another Profile

Use this menu to setup similar profiles quickly, by copying a profile toanother one.

Selectable Values: A to Q.

Editing the tolerance Alarm Time

Use this menu to set a tolerance time that applies to the entire profile.

When the segment goes out of tolerance,

• The segment goes into tolerance hold

• The segment timer holds

• The loop’s single loop display shows TOHO (Tolerance Hold)

When the segment has been out of tolerance for more than the tolerancealarm time,

• The controller goes into tolerance alarm

• The tolerance timer resets

You must acknowledge the tolerance alarm by pressing the ALARMACK key before you can do any other editing.

Selectable Values: 0:00 to 99:59 (minutes or hours, depending on thetime base setting).

LOOP PROCESS UNITS


COPY SETUPFROM PROFILE? A

LOOP PROCESS UNITS


A OUT-OF-TOLRNCEALARM TIME? 1:00



Editing the Ready Setpoint

When you assign a profile to a loop, the profile doesn’t startimmediately; instead, it goes to the ready segment (segment 0) and staysthere until you put the profile in Start mode.

You can set a setpoint, assign events, and set event states for the readysegment. Use this menu to set the ready segment setpoint.

Selectable Values: -999 to 9999, or Off.

Editing the Ready Event States

Use this menu to set the ready state for all outputs that are not used forcontrol or for the SDAC clock. When you assign a profile, the controllerstarts the ready segment: it goes to the ready setpoint and puts all theoutputs in the ready state you set here. The outputs stay in the readystate until the end of segment 1, when segment 1’s events becomeactive.

When you press NO, you will advance to the next menu. If you pressYES, this menu appears:

Selectable Values: You can toggle inputs that are not IN USE to On orOff.

LOOP PROCESS UNITS


A READY SEGMENT

SETPOINT ? OFF

LOOP PROCESS UNITS


B READY SEGMENTEDIT EVENTS?

LOOP PROCESS UNITS


READY EVENTOUTPUT 15? OFF



Choosing an External Reset Input

Use this menu to select an external reset input. Toggle the input to reseta profile to Ready state when it is in Run, Hold, or Wait mode. You canmake any of the eight digital inputs the external reset input.

Selectable Values: 1-8, or N (for no external reset).

Editing a Segment

Each profile is made up of several segments (up to 20). Use this menu tochoose the segment to edit.

Selectable Values: 1-20.

The first time you use this menu, it defaults to segment 1. when youhave finished editing a segment, the controller returns you to this menuand goes to the next segment. This loop continues until you make asegment the last segment of a profile.

Setting Segment Time

Use this menu to change the segment time.

Selectable Values: 000:00 to 999:59 (minutes or seconds, depending onthe selected time base).

LOOP PROCESS UNITS


C EXTERNAL RESETINPUT NUMBER ? N

LOOP PROCESS UNITS


D EDIT SEGMENTNUMBER ? 15

LOOP PROCESS UNITS


B SEGMENT 11SEG TIME? 000:00



Setting a Segment Setpoint

Use this menu to set a setpoint for the segment you are editing. Theprocess will go to this setpoint by the end of the segment time.

Selectable Values: -999 to 9999, or Off (no segment setpoint).

Configuring Segment Events

You can assign up to four digital outputs—Events—to each segment.When the segment ends, the events you select go to the output state youspecify. Use this menu to select events and specify their output states.

Selectable Values: YES or NO.

Starting a segment with an event

If you want a segment to start with an event (usually events happen atthe end of the segment), program the previous segment for the event.You can also use this trick:

1. Setup the segments that come before the first segment.

2. Setup an extra segment with time 000:00 and with the events for the first segment.

3. Setup the first segment.

If you also want to have events at the end of the segment, or you wantthe event to go off at the end of the segment, setup the first segment withthe desired event number and event output state.

LOOP PROCESS UNITS


C SEGMENT 5SEG SETPT ? OFF

LOOP PROCESS UNITS


A SEGMENT 5EDIT SEG EVENTS?



Editing Event Outputs

This menu appears only if you answered YES to the previous menu. Useit to assign a digital output to each event. Assign digital outputs that arenot being used for PID control or for SDAC clock.

Selectable Values: Any digital output from 1 to 34, except those INUSE, or None (no event).

Changing Event States

Use this menu to assign an output state to each event: On (High) or Off(Low). When the event occurs, the output goes to the state you assignhere.

Selectable Values: Off (Low) or On (High).

Editing Segment Triggers

Each segment has two triggers (digital inputs). One of these triggersmust be true before the segment can begin. If a segment times out and atleast one of the next segment’s triggers is not true, the profile goes intotrigger wait state.

Use this menu to edit triggers for the current segment.

Selectable Values: YES (to edit triggers of current segment), or NO (toadvance to the Edit Segment Tolerance menu).

LOOP PROCESS UNITS


A SEG 20 EVENT 3OUTPUT #? 30

LOOP PROCESS UNITS


A SEG14 EV3 DO 4OUTPUT STATE? OFF

LOOP PROCESS UNITS


C SEGMENT 15EDIT SEG TRGGRS?



Assigning an Input to a Trigger

This menu appears only if you answered YES to the Edit SegmentTriggers menu. Use it to assign one of the controller’s eight digitalinputs to a segment trigger. You can assign any digital input to anytrigger. You can also assign the same digital input to multiple triggers.

Selectable Values: Any digital input from 1-8, or None (no inputassigned). Setting a trigger to None disables it.

Changing a Trigger’s True State

Use this menu to toggle a trigger’s true state On or Off. This menuappears only if you answered YES to the Edit Segment triggers menu.

Selectable Values: Off or On.

Latching or Unlatching a Trigger

Use this menu to make a trigger latched or unlatched.

• A latched trigger is checked once, at the beginning of a segment.

• An unlatched trigger is checked constantly while a segment is run-ning. If an unlatched trigger becomes false, the segment timer stops and the loop goes into trigger wait state.

Selectable Values: Latched or Unlatched.

LOOP PROCESS UNITS


C SEG18 TRIG1INPUT NR ?NONE

LOOP PROCESS UNITS


C SEG03 TR2DI09ACTIVE STATE? OFF

LOOP PROCESS UNITS


B SEG01 TR2 DI08TRIG ? UNLATCHED



Setting Segment Tolerance

Use this menu to set a positive or negative tolerance value for eachsegment. this value is displayed in the engineering units of the processand is a deviation from the setpoint.

Tolerance works as shown in this diagram:

If you enter a positive tolerance, the process is out of tolerance when thePV goes above the setpoint plus the tolerance.

If you enter a negative tolerance, the process goes out of tolerance whenthe PV goes below the setpoint minus the tolerance.

Selectable Values: -99 to 99, or Off (no tolerance).

Ending a Profile

Use this menu to make a segment the last one in the profile.

Selectable Values: No or Yes.

Repeating a Profile

Use this menu to set the number of times you want a profile to repeat orcycle.

Selectable Values: 1-99, or C (continuous cycling).

Positive Tolerance Value Negative Tolerance Value

PV out of tolerancePV within tolerance

Setpoint

PV out of tolerance PV within toleranceSetpoint

LOOP PROCESS UNITS


A SEGMENT 01

SEG TOLERNCE?OFF

LOOP PROCESS UNITS


A SEGMENT 01LAST SEGMENT? NO

LOOP PROCESS UNITS


A REPEAT CYCLES ? 1



Using Ramp/Soak

This section explains how to assign a profile to a loop, how to put aprofile in Run, Continue, or Hold mode, how to reset a profile, and howto display profile statistics.

The next figure shows the Ramp/Soak key menus.

From the Ramp/Soak Reset display:

• Press NO to return to Single Loop display.

• Press BACK to return to the Time Remaining display.

Assigning a profile to a loop

Use this menu to assign a profile to a loop.

Assigning a profile the first time

To assign a profile to a loop that doesn’t have a profile, follow thesesteps:

Press R/S Key

Assign Ramp/SoakProfile

If profile is alreadyassigned

Time Remaining

Press R/S Key

Cycle Number

Press R/S Key

Ramp/Soak Mode

Press R/S Key

Ramp/Soak Reset

LOOP PROCESS UNITS


01 ASSIGN R/SPROFILE? A



1. In Single Loop display, switch to the loop you want to edit.

2. Press the RAMP/SOAK key. The assigning menu appears. (See menu in previous page)

3. Choose one of the available profiles and press ENTER.

4. Press BACK if you wish to return to Single Loop display without saving any changes.

Assigning a different profile

To assign a new profile to a loop that already has one assigned, followthese steps:

1. Press the RAMP/SOAK key three times.

2. Press the NO key. You will see the Reset Profile menu.

3. Press YES, then ENTER, to reset the profile. You will see the Assign Profile menu. (See previous page.)

4. Choose one of the available profiles and press ENTER.

5. Press BACK if you wish to return to Single Loop display without saving any changes.

Assigning a Profile to a Linear Input Loop

If you assign a profile to a loop with a linear input, these variables willdepend on the display format setting you chose for the linear input:

• Ready setpoint

• Segment setpoint

• Segment tolerance

Before you assign a profile to a linear input loop, Consult the followingtable.

Display Formatsetting

Effect on Parameter

-999 to 3000 Parameter is as set in profile.

-9999 to 30000 Controller multiplies your parameter by ten.

-999.9 to 3000.0 Controller adds a decimal point and a zero to your parameter.

-99.9 to 300.0 Controller divides your parameter by ten.

-9.999 to 30.000 Controller divides your parameter by 100.

0.999 to 3.00 Controller divides your parameter by 1000.



Running a Profile

When you assign a profile, it does not start running immediately;instead, the loop enters the Ready segment (segment 0). Use this menuto start a profile (put it in Start mode).

Starting a profile

You can start a profile only when it’s in the Ready segment.

1. Press the RAMP/SOAK key repeatedly until you see the Ramp/Soak mode menu.

2. While the profile is in Ready segment, the only mode available is the Run mode.

3. Press YES to start the profile, and then ENTER to advance to the next menu.

Running several profiles simultaneously

To run several profiles simultaneously, follow these steps:

1. Setup the profiles so that segment 1 of each profile has the same latched trigger.

2. Assign the profiles to the appropriate loops. The loops will go to the Ready segment of each profile.

3. Set each profile to Run mode.

4. Trip the trigger.

Editing a profile while it is running

You can edit a profile while it is running, but the changes you havemade will not take effect until the next time it runs.

Ramp/Soak Displays

The Single loop and Bar Graph displays show additional codes for R/Scontrollers.

Single loop display

When the controller is running a profile, the Single Loop display showsthe profile mode where it would usually show MAN or AUTO. The nexttable shows the available codes and their meaning.

LOOP PROCESS UNITS


01 A SEG01/05 RSET MODE? START



This is the Single Loop display when a profile is running.

Bar graph display

Loops that are running R/S profiles have different Bar Graph displaycodes. For these loops, you will see the first letter of each mode wherethe controller would normally display M (for Manual control) or A (forAutomatic control).

The next table shows the codes you would see in loops running R/Sprofiles.

Ramp/Soak Key Displays

Use the RAMP/SOAK key to see the time left in the current profile, theprofile’s status, or the number of times the profile has cycled.

Code Mode

STRT The profile is in the Ready segment.

RUN The profile is running.

HOLD The user has put the profile in Hold mode.

TOHO The profile is in tolerance hold.

WAIT The profile is in trigger wait state.

Code Meaning

R A profile is running.

H A profile is holding.

S A profile is in Ready state.

O A profile is in tolerance hold.

LOOP PROCESS UNITS


02 347 ºF180 RUN 50

Loop number

Process variable

Engineering units

SetpointProfile mode

Output percentage

LOOP PROCESS UNITS


01 08RSHS ROMA

Loop number

Alarm Symbol

R/S mode



All the menus you can reach from the RAMP/SOAK key have the sameinformation on the top line.

How long has the profile run?

From Single Loop display, press the RAMP/SOAK key once.

The next menu appears only if you have already assigned a profile to theloop.

How many times has it cycled?

From Single Loop display, press the RAMP/SOAK key twice. The nextmenu will appear. This menu displays the number of times the profilehas run out of the total number of cycles.

LOOP PROCESS UNITS


01 A SEG01/05 RSET MODE? START

Loop number

Profile letterCurrent segment

Number of segments in profile

Mode(Run/Hold/Continue)

LOOP PROCESS UNITS


04 A SEG10/20 RTIM REM=32:11

LOOP PROCESS UNITS


04 A SEG10/20 RCYCLE NR= 10/15



Holding a Profile or Continuing from Hold

Use the profile mode menu to hold a profile or continue from Hold. Thenext table shows the available modes.

Holding a profile

In Hold mode, all loop parameters stay at their current settings until youchange the mode or reset the profile. To put a profile in hold, followthese steps:

• Press RAMP/SOAK key repeatedly until you see the R/S mode menu.

• While the profile is running, the only mode you will be able select is Hold.

• Press YES to hold the profile, and then ENTER to advance to the next menu.

Continuing a profile

If a profile is holding and you want it to run, you can put it in Continuemode.

• Press RAMP/SOAK key repeatedly until you see the R/S mode menu

• While the profile is holding, the only mode you will be able select is Cont (Continue).

• Press YES to continue the profile, and then ENTER to advance to the next menu.

CurrentMode

Available Mode

Description

Start Run Begin running the assigned profile.

Hold Cont Continue from user-selected hold. Profile runs from the point when you put the profile in Hold

mode. (You cannot continue from a tolerance hold or a trigger wait.)

After you choose this mode, the controller switches back to Run mode.

Run Hold Hold the profile.

LOOP PROCESS UNITS


01 A SEG01/05 RSET MODE? HOLD



Resetting a profile

Use this menu to reset a profile. When you reset a profile, the followinghappens:

• The profile returns to the ready segment. The PV goes to the ready setpoint, and the ready segment events go to the state you specified in the Edit Ready Event State menu.

• The controller shows you the Assign Profile menu in case you would like to assign a different profile to the loop.

To reset a profile, follow these steps:

1. Press RAMP/SOAK key repeatedly until you see the R/S mode menu

2. Press the NO key. You should see the menu below.

3. Press YES to reset the profile, and then ENTER to confirm your choice.:

LOOP PROCESS UNITS


01 A SEG01/05 RSET MODE? RESET


Appendix B: Enhanced Process Control


This Appendix explains five new features added to the CLS and MLScontrollers:

• Process Variable Retransmit

• Cascade Control

• Ratio Control

• Remote Analog Setpoint

• Differential Control

137


Enhanced Process Control Menus

Setup GlobalParameters

SetupLoopInputs

SetupLoop Control Parameters

SetupLoopOutputs

SetupLoop PVRetransmit

SetupLoop Cascade

SetupLoop RatioControl

SetupLoopAlarms

ManualI/OTest

Heat OutputRetrans PV?

Heat RetransMin Inp?

Heat RetransMin Out%?

Heat RetransMax Inp?

Heat RetransMax Out?

Cool Output Retrans PV?

Cool Retrans Min Inp?

Cool Retrans Min Out%?

Cool Retrans Max Inp?

Cool Retrans Max Out?

Enter 1 - 9

Enter 1 - 9

CascadePrim. Loop?

CascadeBase SP?

Cascade Min SP?

Cascade Max SP?

Cascade HT Span?

Cascade CL Span?

Yes

Enter None or No

Enter None or No

Yes

Ratio Control MSTR Loop?

Ratio Control Min SP?

Ratio Control Max SP?

Ratio Control CTRL Ratio?

Ratio Control SP Diff?

Yes

138


Process Variable Retransmit

The PV Retransmit feature allows you to select the PV of any loop inthe controller to be directed to any heat or cool output, including theloop which is providing the PV to be retransmitted. Once an output isdefined as a “PV Retransmit”, it cannot be used for PID control.

Setting Up a PV Retransmit

In order to set up a PV Retransmit, you must configure the followingvariables:

1) PV assignment: the number of the loop that provides the PV for the retransmit calculation.

2) Minimum input: the lowest value of the PV input. If the PV falls below the minimum, the output will stay at the minimum value. This value is expressed in the same engineering units as the input loop.

3) Minimum output: the output value (0-100%) which corresponds to the minimum input.

4) Maximum input: the highest value of the PV input. If the PV goes above the maximum, the output will stay at the maximum value. This value is expressed in the same engineering units as the input loop.

5) Maximum output: the output value (0-100%) which corresponds to the maximum input.

139


By adjusting the Maximum and Minimum inputs, you can scale theoutput appropriately:

PV Retransmit Menus

The Setup menus for the PV Retransmit feature appear under the SetupLoop PV Retransmit menu.

In order to view the PV retransmit menus, you need to select "Yes" atthe following prompt.

If you select "No" to the above screen, the controller skips down to theretransmit for cool. Cool is set up the same way that the heat is set up.

PV Assignment

Selectable Values: Any loop or None (in this case, loop No. 02).

0%

100%

Max.Output

Min.Output

Min.Input

Min.Input

Output(OV%)

Input(PV)

Linear Scaling of PV for Retransmit

LOOP PROCESS UNITS


SETUP LOOP 02PV RETRANSMIT?

LOOP PROCESS UNITS


02 HEAT OUTPUTRETRANS PV? 03

140


Minimum Input

Selectable Values: From the input loop PV minimum reading to themaximum reading.

Minimum Output

NOTE

If you select a Min. Out other than 0%, one output willnever drop below Min. Out, even if the PV drops below theMin. Input you specify.

Selectable Values: 0-100%

Maximum Input

Selectable Values: From the input loop PV minimum reading to themaximum reading.

LOOP PROCESS UNITS


02 HEAT RETRANSMIN INP? 1000

LOOP PROCESS UNITS


02 HEAT RETRANSMIN OUT%? 0%

LOOP PROCESS UNITS


02 HEAT RETRANSMAX INP? 10000

141


Maximum Output

Output will never go above the this Maximum Output percentage,

regardless of how high the PV goes.

Selectable Values: 0-100%.

NOTE

Any available output (heat or cool) may be used as aretransmit output. Any PV (including the same loop num-ber input) may be retransmitted.

LOOP PROCESS UNITS


02 HEAT RETRANSMAX OUT%? 100%

142


Cascade Control

The Cascade control feature allows the output percentage of one controlloop to influence the setpoint of a second control loop.

A loop designated as a Cascade output loop (primary loop) can still beused for direct PID control of an output. A single loop can be either setup as Cascade or Ratio control, but not both. The Cascade output loop isassigned to another control loop (secondary loop), which performs theactual control of the final control element.

Setting Up Cascade Control

In order to set up Cascade control, you need to configure thesevariables:

1) Cascade output assignment. The control output (primary loop num-ber) which will provide the output to the internal controller SP calcu-lation for the secondary loop.

2) Base SP. The SP corresponding to 0% output (heat and cool) from the primary loop. This value is expressed in the same engineering units as the secondary loop PV, adjustable from the minimum reading to the maximum reading.

3) Minimum SP. The lowest value of the secondary loop SP. The mini-mum SP overrides any calculation caused by the primary loop calling for a lower SP. This value is expressed in the same engineering units as the secondary loop PV, adjustable from the minimum reading to the maximum reading.

4) Maximum SP. The highest value of the secondary loop SP. The max-imum SP overrides any calculation caused by the primary loop call-ing for a higher SP. This value is expressed in the same engineering units as the secondary loop PV, adjustable from the minimum reading to the maximum reading.

5) Heat cascade span. The multiplier which is applied to the primary loop heat output percentage. The default value = Maximum SP - Base SP). The range is -9999 to +9999.

6) Cool cascade span. the multiplier which is applied to the primary loop cool output percentage. The default value = Minimum SP - Base SP). The range is -9999 to +9999.

143


7) By adjusting the SP parameters, the user can adjust the influence the primary loop has on the SP of the secondary loop.

Cascade Control Menus

The Setup menus for the Cascade control feature appear under the SetupLoop Cascade main menu (See Setup section in this manual).

In order to view the Cascade control menus, you need to choose "Yes"on the following menu.

Answering YES to this prompt will allow you to set up the Cascadeparameters with the loop currently displayed which performs the actualcontrol of the final control element.

Cascade Output Assignment

Selectable Values: Any loop except the secondary loop (in this case,loop No. 02).

Primary loop output

Calculation of new secondary loop setpoint:

SP=(base sp) + (primary heat output) * (heat span)+(primary cool output) * (cool span)

Secondary LoopMin setpoint

Max setpoint

LOOP PROCESS UNITS


SETUP LOOP 02

CASCADE?

LOOP PROCESS UNITS


02 CASCADEPRIM. LOOP? 03

144


Base Setpoint

Selectable Values: From the secondary loop PV minimum reading tothe maximum reading.

Minimum Setpoint


Maximum Setpoint


Heat Cascade Span

Selectable Values: Maximum setpoint to Base setpoint.

LOOP PROCESS UNITS


02 CASCADEBASE SP? 25

LOOP PROCESS UNITS


02 CASCADEMIN SP? 25

LOOP PROCESS UNITS


02 CASCADEMAX SP? 180

LOOP PROCESS UNITS


02 CASCADEHT SPAN? +9999

145


Cool Cascade Span

Selectable Values: -9999 to 9999.

NOTECascade control cannot be used on the same control loop asRatio control; however, both features may be used in thesame multi-loop controller.

LOOP PROCESS UNITS


02 CASCADECL SPAN? +9999

146


Ratio control

Ratio control allows you to specify a process variable of one loop,(Master loop), multiplied by a Ratio, to be the SP of another loop (Ratioloop). A single loop can be either set up as Cascade or Ratio control, butnot both. You can assign any Process Variable to determine the SP of aRatio loop.

Setting Up Ratio Control

In order to set up Ratio control, you must configure the followingvariables:

1) Ratio Process Variable assignment. The Master loop PV which will provide the output to the internal controller SP calculation for the Ratio loop SP.

2) Minimum SP. The lowest allowable value of the Ratio loop SP. The minimum SP overrides any calculation caused by the Ratio calcula-tion calling for a lower SP. This value is expressed in the same engi-neering units as the Ratio loop PV, adjustable from the minimum reading to the maximum reading.

3) Maximum SP. The highest allowable value of the Ratio loop SP. The maximum SP overrides any calculation caused by the Ratio calcula-tion calling for a higher SP. This value is expressed in the same engi-neering units as the Ratio loop PV, adjustable from the minimum reading to the maximum reading.

4) Control Ratio. The multiplier which is applied to the Master loop PV.

5) SP Differential. The amount to be added or subtracted from the Ratio loop SP calculation before it is used as a SP. This value is expressed in the same engineering units as the Ratio loop PV, adjustable from the minimum reading to the maximum reading.

By adjusting the Ratio control parameters, you can adjust the influencethe Master loop PV has on the SP of the Ratio loop.

Calculation of new Ratio loop SP

SP = (SP Differential) + (Master PV)*(Control Ratio)

Master loop Process Variable

Ratio LoopMin setpoint

Max setpoint

147


Ratio Control Menus

The Ratio control parameters appear under a new menu option, whichfollows the Cascade menu:

Answering YES to this prompt will allow you to set up the Ratio controlparameters with loop number 02 as the Ratio loop, which performs theactual control of the final control element.

Ratio PV Assignment

Selectable Values: You may select from all the loops in the controllerexcept the loop currently selected (in this example loop 02). ChooseNONE for no Ratio control.

Minimum Setpoint

Selectable Values: From the ratio loop PV minimum reading to themaximum reading.

Maximum Setpoint


Control Ratio

Selectable Values: 0.1 to 999.9.

LOOP PROCESS UNITS


SETUP LOOP 02RATIO CONTROL?

LOOP PROCESS UNITS


02 RATIO CONTROLMSTR LOOP? NONE

LOOP PROCESS UNITS


02 RATIO CONTROL MIN SP? 25

LOOP PROCESS UNITS


02 RATIO CONTROLMAX SP? 25

LOOP PROCESS UNITS


02 RATIO CONTROLCTRL RATIO? 1.0

148


Setpoint Differential


NOTE

Ratio control cannot be used on the same control loop asCascade control; however, both features may be used in thesame multi-loop controller.

Remote Analog setpoint

The Remote Analog Setpoint (Remote SP) is set up identically to theRatio control. If you wish to use a Remote SP, an analog input from oneof the control loops is typically connected to an external current orvoltage source, which can be defined as Linear. All other input types arealso usable as Remote SP inputs.

The loop which contains the Remote SP input is the “Master loop“, andthe Ratio control parameters are set up as outlined in the Ratio controlsection of this appendix.

Differential Control

Differential control is a function you enable through the Ratio controlfeature, which allows a process to be controlled at a difference toanother process. You enable the Differential control by setting the Ratiovalue to 1.0 and adjusting the differential to accommodate the desiredoffset.

LOOP PROCESS UNITS


02 RATIO CONTROL

SP DIFF.? 0

149


Typical Applications

This section provides usage examples of the Enhanced features for theCLS and MLS manuals.

Process Variable Retransmit

The Process Variable Retransmit [PVR] feature providesretransmission of the process signal of one channel [primary] via thecontrol output of another channel [secondary]. This signal is a linearoutput signal which is proportional to the engineering units of theprimary channel input.

The controller output signal must be connected to a DAC converter inorder to get an analog signal of 4-20 MAdc or 0-5 Vdc. The type ofDAC ordered depends on application requirements.

Some typical uses would be for data logging to older style analogrecording systems, or long distance transmission of the primary signalto avoid degradation of the primary signal. The signal can also be usedas an input to other types of control systems such as a PLC.

An 8CLS controls the temperature of a furnace. The thermocouple inone of the zones is connected to the CLS and is used for closed-loopPID control. An analog recorder data logging system is also in place,and a recording of the process temperature is required. The recorderinput is a linear 4-20mAdc signal representing a range of 0-1000ºF..

150


1) First, set up the standard control loop parameters according to the fur-nace application, in this case on loop 1.

2) Select another unused PID output for retransmitting the thermocouple value (for example, loop 2 heat output).

3) Change the display to loop 2, and then enter the 3-key sequence to display the following:

Display User Input

Press Yes.

Enter 01 for loop 01 PV. Press Enter.

Enter the minimum input value, which will correspond to the minimum output percentage.

For a range of 0-1000 °F, the minimum input value is 0 °F. Change the MIN INP to 0. Press Enter.

Enter the minimum output percentage, from 0 to 100%. For this example we will assume a full span with a minimum of 0%.Press Enter.

Enter the maximum input value, which corresponds to the maximum output per-centage.

For a range of 0-1000 °F, the maximum input value is 1000 °F. Change the MAX INP to1000. Press Enter.

LOOP PROCESS UNITS


SETUP LOOP 02PV RETRANSMIT?

LOOP PROCESS UNITS


02 HEAT OUTPUTRETRANS PV? 01

LOOP PROCESS UNITS


02 HEAT RETRANSMIN INP? 0

LOOP PROCESS UNITS


02 HEAT RETRANSMIN OUT%? 0

LOOP PROCESS UNITS


02 HEAT RETRANSMAX INP? 1000

151


Now press the "Back" key several times until the normal loop displayappears. The Process Variable Retransmit will now produce an outputon Channel 2 Output which is linear and proportional to Channel 1Process Variable.

This is not a T/C curve type of signal and requires a linear input range inthe recorder.

To complete this configuration, the Channel 2 Output must be enabledand tailored to meet the requirements of the data-application. In thisexample using a data logging recorder, the data-logger will most likelyrequire an analog output 4-20 mA, or 0-1 Vdc, or 1-5 Vdc, or 0-5 Vdc.

The CLS/MLS line of controllers must be used with an Watlow AnafazeDual Dac [Digital to Analog Converter] or SDAC (Serial Digital toAnalog Converter) for proper signal conversion.

The Dual Dac accuracy on retransmit is .75% of reading which matchesthe standard T/C rated accuracy statement of .75% of reading.

For higher accuracies of .05% of full scale, the SDAC is recommended.

Please consult the SETUP Section of this manual for information onsetting up the other options of the controller.

Enter the maximum output percentage, from 0 to 100%. For this example we will assume a full span with a maximum of 100%.Press Enter.

The PV retransmit section of the CLS programming is now completed. You are not using the cool output of loop 2 for retransmitting a PV, so choose None.Press Enter.

Display User Input

LOOP PROCESS UNITS


02 HEAT RETRANSMAX OUT%? 100

LOOP PROCESS UNITS


02 COOL OUTPUTRETRANS PV? NONE

152


Cascade Control

Cascade Control is used to control thermal systems with long lag times,which cannot be as accurately controlled with a single control loop. Theoutput of the first (primary) loop is used to adjust the setpoint of thesecond (secondary) loop. The secondary loop normally executes theactual PID control.

In some applications, there are two zone cascade control systems wherethe primary channel PID output is used for the primary heat control andthe secondary cascaded channel PID output is used for a heat boost in asecond zone. These are used in the metals market such as aluminumcasting industries. You can use the primary heat output for both controland for determining the setpoint of the secondary loop.

A customer has a tank of water, which has an inner and outerthermocouple. The inner thermocouple is located in the center of thewater. The outer thermocouple is located near the heating element. Thedesired temperature of the water is 150ºF, which is measured at theinner thermocouple. Using cascade, the inner thermocouple is used onthe primary loop (in this example, PID loop 1), and the outerthermocouple is used on the secondary loop (PID loop 2). The heaterwill be controlled by loop 2 with a SP range of 150-190 ºF..

Using the 4CLS Watlow Anafaze controller equipped with theEnhanced Control Option firmware, the programming sequence isdescribed below.

W a terLoop 1 Input PV

Loop 1 = Prim ary Cascade LoopLoop 2 = Secondary Cascade Loop

Inner T/C

O uter T/C

Loop 2 Input PV Loop 2 PID Output

Heater

150 F

C L S

Power Control

153


First, switch the controller to display loop 2, which will be thesecondary loop, and then enter the 3-key sequence to display thefollowing:

Display User Input

Press Yes to setup the Cascade parame-ters with loop 2 as the secondary loop.

Enter 01 to make loop 1 the primary loop.Press Enter.

The base setpopint corresponds to the 0% level output of the primary channel. Enter the base SP of the secondary loop. For this example we will assume a base SP of 150°F, which is the desired water temper-ature.Press Enter.

Enter the minimum SP of the secondary loop. For this example we will use a mini-mum SP of -350°F. Normal cascade applications will not require this to be changed.Press Enter.

Enter the maximum SP of the secondary loop. For this example we will use a max-imum SP of 1400°F. Normal cascade applications will not require this to be changed.Press Enter.

LOOP PROCESS UNITS


SETUP LOOP 02

CASCADE?

LOOP PROCESS UNITS


02 CASCADE

PRIM. LOOP? 01

LOOP PROCESS UNITS


02 CASCADE

BASE SP? 150

LOOP PROCESS UNITS


02 CASCADE

MIN SP? -350

LOOP PROCESS UNITS


02 CASCADE

MAX SP? 1400

154


Now press the "Back" key several times until the normal loop displayappears. The output percentage of loop 1 will now control the setpointof loop 2. You may set Channel 1 to Manual and the Output to 0%,Channel 2 SP should =150. Adjust Channel 1 Manual Output to 50%,Channel 2 SP should =170. Adjust Channel 1 Manual Output to 100%,Channel 2 SP should =190.

To complete the cascade setup, both loop 1 and loop 2 must beconfigured for inputs, outputs, and alarms.

In addition, the PID parameters of loop 1 must be tuned to produce thedesired effect for the application on the setpoint of loop 2. For a cascadecontrol application that uses the secondary loop for PID control, thenLoop 1 must use only proportional mode. This must be set for theamount of change in the PV to cause a 100% change in the output level.

It is necessary for the temperature of Loop 1 temperature to drop only10 ºF in order for Loop 2 to change from 150 to 190 ºF. Then set the PBof loops 1 to 10, and turn off Intergal and Derivative terms by setting TIand TD to 0.

The PID parameters of loop 2 must be tuned to perform efficientcontrol.

For two-zone cascade control systems, the PID settings for both loops,the primary plus the secondary, must be optimized for good temperaturecontrol.

Please consult the SETUP Section of this manual for information ontuning PID loops.

Enter the heat span of the secondary loop. This is the span over which the primary output from 0-100% is used to change the setpoint. For this example we will assume a linear rise in SP, so the heat span is 40°F.Press Enter.

Enter the cool span of the secondary loop. For this example we will assume no low-side adjustment to the SP, so the cool span is 0°F.Press Enter.

Display User Input

LOOP PROCESS UNITS


02 CASCADE

HT SPAN? 40

LOOP PROCESS UNITS


02 CASCADE

CL SPAN? 0

155


Ratio Control

A chemical process requires a formula of two parts Water (H2O) to one

part Potassium Hydroxide (KOH) to produce diluted PotassiumHydroxide. The desired flow of H2O is 10 gallons per second (gps), andthe KOH should be 5 gps. Each chemical has a pipe feeding a commonpipe. The flow rate of each feeder pipe is measured and supplied to a4CLS, with H2O flow as PV1 and KOH flow as PV2. The outputs ofloops 1 and 2 adjust motorized valves.

1) Adjust and tune Loop 1 (H2O) for optimal performance before implementing the Ratio setup.

2) Switch the controller to display loop 2 (KOH), and then enter the 3-key sequence to display the following:

Display User Input

Press Yes to setup the Ratio parameters for loop 02.

Assign loop 01 to be the master loop.

Press Enter.

LOOP PROCESS UNITS


SETUP LOOP 02

RATIO CONTROL?

LOOP PROCESS UNITS


02 RATIO CONTROL

MSTR LOOP? 01

156


Now press Back several times until the normal loop display appears.

The setpoint of loop 2 will now be equal to one half of the processvariable of loop 2. To complete the ratio setup, configure both loops 1and 2 for inputs, outputs, and alarms. Please consult the Setup section ofthe manual for information on PID loop setup.

Enter the minimum Ratio loop SP. For this example, we will use 0 gallons per minute as a minimum

Press Enter.

Enter the maximum Ratio loop SP. For this example, we will use 7.0 gallons per minute as a maximum

Press Enter.

Enter the control ratio, which is the mul-tiple applied to the master Process Vari-able (the H2O flow rate is multiplied by 0.5 to obtain the KOH flow rate set-point).

Press Enter.

Enter the setpoint differential (or offset). For this example we have no offset requirement and will use 0

Press Enter.

Display User Input

LOOP PROCESS UNITS


02 RATIO CONTROL

MIN SP? 0.0

LOOP PROCESS UNITS


02 RATIO CONTROL

MAX SP? 7.0

LOOP PROCESS UNITS


02 RATIO CONTROL

CTRL: RATIO? 0.5

LOOP PROCESS UNITS


02 RATIO CONTROL

SP DIFF.? 0

157


Remote Setpoint

Remote Setpoint can be used to allow external equipment, such as aPLC or other control system, to provide an analog output (4-20 mA, 0-5Vdc, etc.) used to change the setpoint of a loop. The method ofconfiguring the Remote Setpoint is the same as Ratio Control. In theprevious example, loop 1 would be the remote analog value and loop 2would be the PID control loop.

Both the remote setpoint feature and the PV retransmit feature can beused with PLC systems as the link between multi-loop PID controlsystems and PLC systems.

For example, a 0-5 Vdc signal representing 0-300 ºF will be used as aremote SP input to the CLS. The input signal will be received on Loop 1with the control being performed on Loop 2. Note that proper scalingresisters must be installed on the input of Loop 1 to allow it to accept a0-5Vdc input.

From the loop 1 input channel, select the Linear Input Type. Set HiPV =300, LoPV =0, HiRDG = 100.0%, and LoRDG = 0.0%.

Next go to loop 2 and enter the programming menus. Go to the RatioOption Menu and press the YES key to select the Ratio Menu.

Display User Input



Press Enter.

Enter the minimum Ratio loop SP. For this example, we will use 0 ºF.

Press Enter.

LOOP PROCESS UNITS


SETUP LOOP 02

RATIO CONTROL?

LOOP PROCESS UNITS


02 RATIO CONTROL

MSTR LOOP? 01

LOOP PROCESS UNITS


02 RATIO CONTROL

MIN SP? 0

158


Now press the "Back" key several times until the normal loop displayappears. The setpoint of loop 2 will now be equal to the Input range ofLoop 1, which is 0-5 Vdc which is representative of the 0-300 ºF.

To complete the Remote SP setup, Loop 1 may be configured foroutputs and alarms. Likewise, Loop 2 must be configured for inputs,outputs, and alarms.

Please consult the SETUP Section of this manual for information onPID loop setup.

Differential Control

Differential Control is a simple application of the Ratio Control option,used to control one process at a differential (or offset) to another.

A thermal forming application requires that the outside heaters operateat a higher temperature than the center heaters. In some applicationsthese may be in bands of temperatures. The diferential control point isdetermined by the Master channel which is using IR sensors fortemperture feedback. Secondary loops will be using T/Cs for feedback.

Enter the maximum Ratio loop SP. For this example, we will use 300 ºF as a maximum

Press Enter.

Enter the control ratio, which is the mul-tiple applied to the master Process Vari-able. In this example the ration is 1.0.

Press Enter.

Enter the setpoint differential (or offset). For this example we have no offset requirement and will use 0

Press Enter.

Display User Input

LOOP PROCESS UNITS


02 RATIO CONTROL

MAX SP? 300

LOOP PROCESS UNITS


02 RATIO CONTROL

CTRL: RATIO? 1.0

LOOP PROCESS UNITS


02 RATIO CONTROL

SP DIFF.? 0

159


The loops using the IR sensor as an input is assigned to the Master Loopin the Ratio Control Option Menu. The secondary loop is theDifferential control loop. By setting the setpoint differential "SP DIFF."to the desired offset, this will produce the desired offset between thesecondary and master loop setpoints for differential control.

For example setpoints, the Master Loop can be controlled at 325 ºF andthe secondary loop at 375 ºF by using a differential of 50 ºF.

Channel 1 must be set up for PID control of the SP at 325 ºF.

Go to Channel 2 and enter the programming menus. Go to the RatioOption Menu and press the YES Key to select the Ratio Menu.

Display User Input



Press Enter.

Enter the maximum Ratio loop SP. For this example, we will use 400 ºF as a maximum

Press Enter.

Enter the minimum Ratio loop SP. For this example, we will use 300 ºF.

Press Enter.

LOOP PROCESS UNITS


SETUP LOOP 02

RATIO CONTROL?

LOOP PROCESS UNITS


02 RATIO CONTROL

MSTR LOOP? 01

LOOP PROCESS UNITS


02 RATIO CONTROL

MAX SP? 400

LOOP PROCESS UNITS


02 RATIO CONTROL

MIN SP? 300

160


Now press the "Back" key several times until the normal loop displayappears. The setpoint of loop 2 will now be equal to SP of Loop 1 plus50 ºF.

To complete the Differential Control setup, Loop 1 and Loop 2 must beconfigured for inputs, outputs, and alarms. Please consult The SETUPSection of the manual for information on PID loop setup.

Enter the control ratio, which is the mul-tiple applied to the master Process Vari-able. In this example the ration is 1.0.

Press Enter.

Enter the setpoint differential (or offset). For this example we have an offset of +50.

Press Enter.

Display User Input

LOOP PROCESS UNITS


02 RATIO CONTROL

CTRL: RATIO? 1.0

LOOP PROCESS UNITS


02 RATIO CONTROL

SP DIFF.? 50

161


162

Glossary
A
ACSee Alternating Current.

AC Line FrequencyThe frequency of the AC power line measured inHertz (Hz), usually 50 or 60 Hz.

AccuracyCloseness between the value indicated by a mea-suring instrument and a physical constant orknown standards.

ActionThe response of an output when the process vari-able is changed. See also Direct action, Reverseaction.

AddressA numerical identifier for a controller when usedin computer communications.

AlarmA signal that indicates that the process hasexceeded or fallen below a certain range aroundthe setpoint. For example, an alarm may indicatethat a process is too hot or too cold. See also:

Deviation AlarmFailed Sensor AlarmGlobal AlarmHigh Deviation AlarmHigh Process AlarmLoop AlarmLow Deviation AlarmLow Process Alarm

Alarm DelayThe lag time before an alarm is activated.

Alternating Current (AC)An electric current that reverses at regular inter-vals, and alternates positive and negative values.

Ambient TemperatureThe temperature of the air or other medium thatsurrounds the components of a thermal system.

American Wire Gauge (AWG)A standard of the dimensional characteristics ofwire used to conduct electrical current or signals.AWG is identical to the Brown and Sharpe(B&S) wire gauge.

AmmeterAn instrument that measures the magnitude of anelectric current.

Ampere (Amp)A unit that defines the rate of flow of electricity(current) in the circuit. Units are one coulomb(6.25 x 1018 electrons) per second.

Analog OutputA continuously variable signal that is used to rep-resent a value, such as the process value or set-point value. Typical hardware configurations are0-20mA, 4-20mA or 0-5 Vdc.

Automatic ModeA feature that allows the controller to set PIDcontrol outputs in response to the Process Vari-able (PV) and the setpoint.

AutotuneA feature that automatically sets temperaturecontrol PID values to match a particular thermalsystem.

B

BandwidthA symmetrical region above and below the set-point in which proportional control occurs.

Baud RateThe rate of information transfer in serial commu-nications, measured in bits per second.

163

Glossary

Block Check Character (BCC)A serial communications error checking method.An acceptable method for most applications,BCC is the default method. See CRC.

Bumpless TransferA smooth transition from Auto (closed loop) toManual (open loop) operation. The control outputdoes not change during the transfer.

C

CalibrationThe comparison of a measuring device (anunknown) against an equal or better standard.

Celsius (Centigrade)Formerly known as Centigrade. A temperaturescale in which water freezes at 0°C and boils at100°C at standard atmospheric pressure. The for-mula for conversion to the Fahrenheit scale is:°F=(1.8x°C)+32.

Central Processing Unit (CPU)The unit of a computing system that includes thecircuits controlling the interpretation of instruc-tions and their execution.

CircuitAny closed path for electrical current. A configu-ration of electrically or electromagnetically-con-nected components or devices.

Closed LoopA control system that uses a sensor to measure aprocess variable and makes decisions based onthat feedback.

Cold JunctionConnection point between thermocouple metalsand the electronic instrument.

Common Mode Rejection RatioThe ability of an instrument to reject electricalnoise, with relation to ground, from a commonvoltage. Usually expressed in decibels (dB).

CommunicationsThe use of digital computer messages to linkcomponents.See Serial Communications.See Baud Rate.

Control ActionThe response of the PID control output relative tothe error between the process variable and thesetpoint. For reverse action (usually heating), asthe process decreases below the setpoint the out-put increases. For direct action (usually cooling),as the process increases above the setpoint, theoutput increases.

Control ModeThe type of action that a controller uses. Forexample, On/Off, time proportioning, PID, Auto-matic or manual, and combinations of these.

CurrentThe rate of flow of electricity. The unit of mea-sure is the ampere (A). 1 ampere = 1 coulomb per second.

Cycle TimeThe time required for a controller to completeone on-off-on cycle. It is usually expressed inseconds.

Cyclic Redundancy Check (CRC)An error checking method in communications. Itprovides a high level of data security but is moredifficult to implement than Block Check Charac-ter (BCC). See Block Check Character.

D

Data LoggingA method of recording a process variable over aperiod of time. Used to review process perfor-mance.

DeadbandThe range through which a variation of the inputproduces no noticeable change in the output. Inthe deadband, specific conditions can be placedon control output actions. Operators select thedeadband. It is usually above the heating propor-tional band and below the cooling proportionalband.

164

Glossary

Default ParametersThe programmed instructions that are perma-nently stored in the microprocessor software.

Derivative Control (D)The last term in the PID algorithm. Action thatanticipated the rate of change of the process, andcompensates to minimize overshoot and under-shoot. Derivative control is an instantaneouschange of the control output in the same directionas the proportional error. This is caused by achange in the process variable (PV) thatdecreases over the time of the derivative (TD).The TD is in units of seconds.

Deutsche Industrial Norms (DIN)A set of technical, scientific and dimensionalstandards developed in Germany. Many DINstandards have worldwide recognition.

Deviation AlarmWarns that a process has exceeded or fallenbelow a certain range around the setpoint.

Digital to Analog Converter (DAC)A device that converts a numerical input signal toa signal that is proportional to the input in someway.

Direct ActionAn output control action in which an increase inthe process variable, causes an increase in theoutput. Cooling applications usually use directaction.

Direct Current (DC)An electric current that flows in one direction.

Distributed Zero Crossing (DZC)A form of digital output control. Similar to burstfire.

E

Earth GroundA metal rod, usually copper, that provides anelectrical path to the earth, to prevent or reducethe risk of electrical shock.

Electrical NoiseSee Noise.

Electromagnetic Interference (EMI)Electrical and magnetic noise imposed on a sys-tem. There are many possible causes, such asswitching ac power on inside the sine wave. EMIcan interfere with the operation of controls andother devices.

Electrical-Mechanical RelaysSee Relay, electromechanical.

EmissivityThe ratio of radiation emitted from a surfacecompared to radiation emitted from a blackbodyat the same temperature.

Engineering UnitsSelectable units of measure, such as degrees Cel-sius and Fahrenheit, pounds per square inch,newtons per meter, gallons per minute, liters perminute, cubic feet per minute or cubic meters perminute.

EPROMErasable Programmable, Read-Only Memoryinside the controller.

ErrorThe difference between the correct or desiredvalue and the actual value.

F

FahrenheitThe temperature scale that sets the freezing pointof water at 32ºF and its boiling point at 212ºF atstandard atmospheric pressure. The formula forconversion to Celsius is: ºC=5/9 (ºF-32ºF).

Failed Sensor AlarmWarns that an input sensor no longer produces avalid signal. For example, when there are thermo-couple breaks, infrared problems or resistance

165

Glossary

temperature detector (RTD) open or short fail-ures.

FilterFilters are used to handle various electrical noiseproblems.

Digital Filter (DF) — A filter that allows theresponse of a system when inputs change unreal-istically or too fast. Equivalent to a standardresistor-capacitor (RC) filter

Digital Adaptive Filter — A filter that rejectshigh frequency input signal noise (noise spikes).

Heat/Cool Output Filter — A filter that slowsthe change in the response of the heat or cool out-put. The output responds to a step change bygoing to approximately 2/3 its final value withinthe numbers of scans that are set.

FrequencyThe number of cycles over a specified period oftime, usually measured in cycles per second. Alsoreferred to as Hertz (Hz). The reciprocal is calledthe period.

G

GainThe amount of amplification used in an electricalcircuit. Gain can also refer to the Proportional (P)mode of PID.

Global AlarmAlarm associated with a global digital output thatis cleared directly from a controller or through auser interface.

Global Digital OutputsA pre-selected digital output for each specificalarm that alerts the operator to shut down criticalprocesses when an alarm condition occurs.

GroundAn electrical line with the same electrical poten-tial as the surrounding earth. Electrical systemsare usually grounded to protect people and equip-ment from shocks due to malfunctions. Alsoreferred to a "safety ground".

H

Hertz(Hz)Frequency, measured in cycles per second.

High Deviation AlarmWarns that the process is above setpoint, butbelow the high process variable. It can be used aseither an alarm or control function.

High PowerAny voltage above 24 VAC or Vdc and any cur-rent level above 50 mAac or mAdc.

High Process AlarmA signal that is tied to a set maximum value thatcan be used as either an alarm or control function.

High Process Variable (PV)See Process Variable (PV).

High ReadingAn input level that corresponds to the high pro-cess value. For linear inputs, the high reading is apercentage of the full scale input range. For pulseinputs, the high reading is expressed in cycles persecond (Hz).

I

InfraredA region of the electromagnetic spectrum withwavelengths ranging from one to 1,000 microns.These wavelengths are most suited for radiantheating and infrared (noncontact) temperaturesensing.

InputProcess variable information that is supplied tothe instrument.

Input ScalingThe ability to scale input readings (readings inpercent of full scale) to the engineering units ofthe process variable.

166

Glossary

Input TypeThe signal type that is connected to an input, suchas thermocouple, RTD, linear or process.

Integral Control (I)Control action that automatically eliminates off-set, or droop, between setpoint and actual processtemperature.See Auto-reset.

J

JobA set of operating conditions for a process thatcan be stored and recalled in a controller’s mem-ory. also called a Recipe.

JunctionThe point where two dissimilar metal conductorsjoin to forma thermocouple.

L

LagThe delay between the output of a signal and theresponse of the instrument to which the signal issent.

Linear InputA process input that represents a straight linefunction.

LinearityThe deviation in response from an expected ortheoretical straight line value for instruments andtransducers. also called Linearity Error.

Liquid Crystal Display (LCD)A type of digital display made of a material thatchanges reflectance or transmittance when anelectrical field is applied to it.

LoadThe electrical demand of a process, expressed inpower (watts), current (amps), or resistance(ohms). The item or substance that is to be heatedor cooled.

Loop AlarmAny alarm system that includes high and low pro-cess, deviation band, deadband, digital outputs,and auxiliary control outputs.

Low Deviation AlarmWarns that the process is below the setpoint, butabove the low process variable. It can be used aseither an alarm or control function.

Low Process Alarm A signal that is tied to a set minimum value thatcan be used as either an alarm or control function.

Low ReadingAn input level corresponding to the low processvalue. For linear inputs, the low reading is a per-centage of the full scale input range. For pulseinputs, the low reading is expressed in cycles persecond (Hz).

M

Manual ModeA selectable mode that has no automatic controlaspects. The operator sets output levels.

Manual ResetSee Reset.

Milliampere (mA)One thousandth of an ampere.

N

No Key ResetA method for resetting the controller's memory(for instance, after an EPROM change).

NoiseUnwanted electrical signals that usually producesignal interference in sensors and sensor circuits.See Electromagnetic Interference.

Noise SuppressionThe use of components to reduce electrical inter-ference that is caused by making or breakingelectrical contact, or by inductors.

167

Glossary

Non LinearThrough Watlow-Anafaze software, the Non Lin-ear field sets the system to linear control, or toone of two non linear control options. Input 0 forLinear, 1 or 2 for non linear.

O

OffsetThe difference in temperature between the set-point and the actual process temperature. Offsetis the error in the process variable that is typicalof proportional-only control.

On/Off ControlA method of control that turns the output full onuntil setpoint is reached, and then off until theprocess error exceeds the hysteresis.

Open LoopA control system with no sensory feedback.

Operator MenusThe menus accessible from the front panel of acontroller. These menus allow operators to set orchange various control actions or features.

Optical IsolationTwo electronic networks that are connectedthrough an LED (Light Emitting Diode) and aphotoelectric receiver. There is no electrical con-tinuity between the two networks.

OutputControl signal action in response to the differencebetween setpoint and process variable.

Output TypeThe form of PID control output, such as TimeProportioning, Distributed Zero Crossing,SDAC, or Analog. Also the description of theelectrical hardware that makes up the output.

OvershootThe amount by which a process variable exceedsthe setpoint before it stabilizes.

P

Panel LockA feature that prevents operation of the frontpanel by unauthorized people.

PIDProportional, Integral, Derivative. A controlmode with three functions:Proportional action dampens the systemresponse, Integral corrects for droops, and Deriv-ative prevents overshoot and undershoot.

PolarityThe electrical quality of having two oppositepoles, one positive and one negative. Polaritydetermines the direction in which a current tendsto flow.

Process VariableThe parameter that is controlled or measured.Typical examples are temperature, relativehumidity, pressure, flow, fluid level, events, etc.The high process variable is the highest value ofthe process range, expressed in engineering units.The low process variable is the lowest value ofthe process range.

Proportional (P)Output effort proportional to the error from set-point. For example, if the proportional band is20º and the process is 10º below the setpoint, theheat proportioned effort is 50%. The lower thePB value, the higher the gain.

Proportional Band (PB)A range in which the proportioning function ofthe control is active. Expressed in units, degreesor percent of span.See PID.

Proportional ControlA control using only the P (proportional) value ofPID control.

Pulse InputDigital pulse signals from devices, such as opti-cal encoders.

168

Glossary

R

RampA programmed increase in the temperature of asetpoint system.

RangeThe area between two limits in which a quantityor value is measured. It is usually described interms of lower and upper limits.

RecipeSee Job.

Reflection Compensation ModeA control feature that automatically corrects thereading from a sensor.

Relay A switching device.

Electromechanical Relay — A power switch-ing device that completes or interrupts a circuitby physically moving electrical contacts into con-tact with each other. Not recommended for PIDcontrol.

Solid State Relay (SSR) — A switchingdevice with no moving parts that com-pletes or interrupts a circuit electrically.

ResetControl action that automatically eliminates off-set or droop between setpoint and actual processtemperature.See also Integral.

Automatic Reset — The integral function of aPI or PID temperature controller that adjusts theprocess temperature to the setpoint after the sys-tem stabilizes. The inverse of integral.

Automatic Power Reset — A feature in latch-ing limit controls that

ResistanceOpposition to the flow of electric current, mea-sured in ohms.

Resistance Temperature Detector (RTD)A sensor that uses the resistance temperaturecharacteristic to measure temperature. There aretwo basic types of RTDs: the wire RTD, which isusually made of platinum, and the thermistorwhich is made of a semiconductor material. Thewire RTD is a positive temperature coefficientsensor only, while the thermistor can have eithera negative or positive temperature coefficient.

Reverse ActionAn output control action in which an increase inthe process variable causes a decrease in the out-put. Heating applications usually use reverseaction.

RTDSee Resistance Temperature Detector.

S

Serial CommunicationsA method of transmitting information betweendevices by sending all bits serially over a singlecommunication channel.

RS-232—An Electronics Industries of America(EIA) standard for interface between data termi-nal equipment and data communications equip-ment for serial binary data interchange. This isusually for communications over a short distance(50 feet or less) and to a single device.

RS-485—An Electronics Industries of America(EIA) standard for electrical characteristics ofgenerators and receivers for use in balanced digi-tal multipoint systems. This is usually used tocommunicate with multiple devices over a com-mon cable or where distances over 50 feet arerequired.

Setpoint (SP)The desired value programmed into a controller.For example, the temperature at which a systemis to be maintained.

ShieldA metallic foil or braided wire layer surroundingconductors that is designed to prevent electro-static or electromagnetic interference from exter-nal sources.

169

Glossary

SignalAny electrical transmittance that conveys infor-mation.

Solid State Relay (SSR)See Relay, Solid State.

SpanThe difference between the lower and upper lim-its of a range expressed in the same units as therange.

SpreadIn heat/cool applications, the +/- differencebetween heat and cool. Also known as processdeadband.

See deadband.

StabilityThe ability of a device to maintain a constant out-put with the application of a constant input.

T

T/C Extension WireA grade of wire used between the measuringjunction and the reference junction of a thermo-couple. Extension wire and thermocouple wirehave similar properties, but extension wire is lesscostly.

TD (Timed Derivative)The derivative function.

ThermistorA temperature-sensing device made of semicon-ductor material that exhibits a large change inresistance for a small change in temperature.Thermistors usually have negative temperaturecoefficients, although they are also available withpositive temperature coefficients.

Thermocouple (T/C)A temperature sensing device made by joiningtwo dissimilar metals. This junction produces anelectrical voltage in proportion to the differencein temperature between the hot junction (sensingjunction) and the lead wire connection to theinstrument (cold junction).

TI (Timed Integral)The Integral term.

TransmitterA device that transmits temperature data fromeither a thermocouple or RTD by way of a two-wire loop. The loop has an external power sup-ply. The transmitter acts as a variable resistorwith respect to its input signal. Transmitters aredesirable when long lead or extension wires pro-duce unacceptable signal degradation.

U

Upscale Break ProtectionA form of break detection for burned-out thermo-couples. Signals the operator that the thermocou-ple has burned out.

UndershootThe amount by which a process variable fallsbelow the setpoint before it stabilizes.

V

Volt (V)The unit of measure for electrical potential, volt-age or electromotive force (EMF).See Voltage.

Voltage (V)The difference in electrical potential between twopoints in a circuit. It’s the push or pressurebehind current flow through a circuit. One volt(V) is the difference in potential required to moveone coulomb of charge between two points in acircuit, consuming one joule of energy. In otherwords, one volt (V) is equal to one ampere of cur-rent (I) flowing through one ohm of resistance(R), or V=IR.

170

Glossary

Z

Zero CrossAction that provides output switching only at ornear the zero-voltage crossing points of the acsine wave.

171

Glossary

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